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Design and creation of an HMI and a PROFIBUS network

1. interface Assign Monitor modify A var n ea SIMATIC Manager HW config configure harware Aa A A A LAD STL Diagnostic FBD functions program J S7 meee Figure 35 Standard STEP 7 packages e document 3 Each of which does a specific job when programming an automation task such as e Configuring the hardware and settings its parameters e Configuring networks connections and interfaces e Creating and debugging user programs TAMK University of Applied Sciences Software page 29 102 Departement of electrical engineering Additional optional software tools are available to expand the standard STEP 7 package for particular applications These include programming language packages such as SCL S7GRAPH or HiGraph e document 3 4 SIMATIC Manager collects all the data and settings necessary for an automation task and combines this information into a project Within this project all data provides comprehensive online help including context sensitive help for selected folders objects and error messages e document 3 4 STEP 7 project is divided into folders and objects Figure 36 Folders are objects which can contain other folders and objects KA SIMATIC Manager Coiler Drive profibus Fie Edit Insert PLC View Options Window Help D a BP ae Ble Sy Salt EE RM lt NoFiter gt Jy GS S250 m m Coiler Drive profibus A E SIMATIC 300 Sta
2. Ce me Figure 67 LAD STL FBD DB10 configuration The data block can be saved and the window closed The last step is to connect this table DB10 with the reading function Therefore in RECORD the name of our data block has to be set RECORD DB10 Inpudata TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 54 102 Finally here the function Figure 68 with the parameters PROFIBUS parameter data CALL DPRD DAT SFc14 Read Consistent Data of a Standard DP Slave LADDE WAL6A 100 RET AL Mw200 RECORD DB10 Inputdata PADBLIO DBEO O NOP O Figure 68 SFC 14 parameter data function configured For the second reading function create a new network and in the same way create the second reading function for the process data and the data block 31 with only four bytes as shown on Figure 69 and 70 Hei LAD STL FBD DB31 Coiler Drive profibus SIMATIC 300 Station CPU 315 2 DP 1 File Edit Insert PLO Debug View Options Window Help Cees ao He i 0E k Ly adaress name type initial value comment Process reed armarina OO O O O O O O 6 Libraries Figure 69 LAD STL FBD DB31 configuration CALL DPRD DAT SFc14 Read Consistent Data of a Standard DP Slave LADDIE WHLE 108 RET VAL MWz04 RECORD DB31 Process read PHDBI1 DBXO O NOP 0 Figure 70 SFC 14 process data function configured 11 4 2 Writing data of a DP slave d
3. General button settings TAMK University of Applied Sciences Departement of electrical engineering WinCE Projects page 91 102 The last step is to configure the button to show the right screen In our case the trend screen Click on the Events tab and then select Click Then selection the arrow on the right and choose in the Screens menu the Activate Screen function Figure 17 OQ x a saa iti EE Function List d Animations E ActivateScreen fs Events gt Click Recipes w Press Screens m Release gt ActivateFirstChildScreen ms Activat ActivateLeftScreen Deactivate ActivateParentScreen ActivatePreviousScreen m Change ActivateRightScreen ActivateRootScreen ActivateScreen Figure 17 WinCC Events configuration Configure the function with the screen name and valid Figure 18 Button ISJ e BT Switch n apelin kiei EE Function List fg s gt Animadong we ActivateScreen gt pep Screen name Click m Press Object number m Release Fa lt No function gt lt Undefined gt m Activate Cj Control_Panel Screen No 2 m Deactivate O Motor Screen No 4 m Change Cj Screen_1 Screen No 7 O Start Screen No 1 Trend Screen No 3 Figure 18 WinCC Function configuration After this step the button is correctly configured and it can be inserted in the navigation menu TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network config page 9
4. 9 1 4 Transfer to the PLC After programming and saving the project it must be transferred to the PLC It is better to put the controller in STOP statue When the program is loaded put the PLC in RUN P statue and in the ONLINE window the state variables can be directly visualized in the program Some tests are possible with the debug mode In LAD Figure 43 the patterns become dotted with places where the powers fails and the patterns become green where there is powers TAMK University of Applied Sciences Departement of electrical engineering Software page 34 102 i Pott wrt tnt ggg ge MK Mg He a p mmm m X Figure 43 Debugging with LAD e document 5 In FBD Figure 44 the signal state is indicated by 0 and 1 The dotted line means that there is no result of logic operation Green Light Dees Figure 44 Debugging with FBD e document 5 In STL Figure 45 a table is displayed next to the program specifying the values 0 or 1 of the operands For Statement List the following is displayed in tabular form e Result of logic operation RLO e Status bit STA e Standard status STANDARD a A Standard Ke y l FF 0 Key_2 FF T Green Light 0 to ee Figure 45 Debugging with ST e document 5 We can also list the status of all variables or monitor them e document 5 9 1 5 More Helps It is documented in the software menu or F1 but also in the start menu under SIMATIC gt
5. Figure 9 STEP 7 Symbols table When the symbols table is filled double click on the OB1 block to call the LAD STL FBD module Write the code like in the figure 8 in the first network In the second network there is the code to call the reading and writing function for the PROFIBUS network The programming of this network is explained in the chapter 14 Downloading the Program to the Programmable Controller When the hardware configuration and the programming are done all the data have to be sent in the PLC memory into the CPU The first step is to save the project Saving the project allows to check if there are errors Next connect the MPI cable Figure 10 from the PC to the PLC Figure 10 MPI cable TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 81 102 Plug it as on the Figure 11 and turn on the PLC and then the PC Figure 11 PC and PLC connection Click on the online icon 2a or in the View menu click on Online After this step two windows are opened the offline windows already opened shows the situation on the programming device and the online windows shows the situation on the CPU Make sure that the connection is done trying to open the Blocks file in the online window The online or offline status is indicated by the different colour in the headers as seen on the Figure 12 Figure 12 STEP 7 Online window mode Select the Block fol
6. REF All the details for the CW and the REF parameter can be found in the Vacon manual e document 16 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 63 102 11 8 Example of data exchange through the PROFIBUS network Take a practical example where the motor has to be started with 50 of its speed reference and the parameter maximum frequency has to be read As seen in the previous chapter in the parameter field the ID has to be set in reading mode 10 and with the ID parameter 66 hex for our example 66 hex 102 dec maximum frequency The Index parameter is not used so it will have 00 00 and the value is also set with 00 00 For the process field to start the motor the code 04 7F has to be used To start the motor with 50 of its speed the REF parameter has to contain the value 50 00 In hexadecimal format it is 13 88 hex The Figure 88 is asummary of the frame to send IO 1046 hex 1 Read parameter value 046 Parameter 102 e g maximum frequency IND 0000 hex 0000 No meaning VALUE 0000 0000 hex 0000 0000 No meaning CW 047F hex 04 7F Start command see chapter control word and state ma chine REF 1388 hex Speed ref 50 00 25 00 Hz if parameter min frequency 0 Hz and max frequency 50 Hz PPO frame 10 js oo joo oo oo oo oo os 7F_ 13 88 Figure 88 PPO 1 frame e document 16 To send these different values into the freq
7. Three examples of modular PLCs are shown in the Figures 22 23 and 24 Figure 22 Simatic S7 300 Figure 23 SLC 500 Figure 24 Modicon M340 Siemens Rockwell Schneider The intern structure of a PLC is shown in the Figure 25 Interfaces Monitor ROM Program EPROM Central unit Accumulator Register 1 vr un f Aritmetic Ordinal counter bd Unit Decoder Register n i Logic Register 2 Power supply i Figure 25 The intern structure of a PLC e document 16 TAMK University of Applied Sciences Departement of electrical engineering PLC page 19 102 6 3 Processor It is like a heart for the PLC it is in the central unit CU and its performances depend on the processor s powerfulness The central unit is an electronic card builds around processor ship s and provides this kind of functions e Logical operations on bits or on words e Temporisation and counting There are three different types of realization e Wire technology the fastest but the most expensive too only for particular purpose e Microprocessor technology the cheapest because uses microprocessor produced in large number e Mixed technology some operations are with wire to raise the speed To provide the connection between the CU and the I O cards it must have a coupler e document 16 6 4 Input Output module I O They provide the interface role of the command uni
8. national standard became the international EN 50170 standard in Europe since 1999 PROFIBUS is even in the international CEI 61158 standard and it takes an important place in the global market of field bus There are more than 15 millions devices installed in 1 millions of network and allows to answer to a large type of applications as such on the Figure 58 Manufacturing Continue Building Process Process Management Robotics Warhousing Figure 58 Applications with PROFIBUS network e document 16 PROFIBUS is composed of three variants called 11 1 1 PROFIBUS FMS Field Message Specification First PROFIBUS application used it is an application with an exchange between the masters to synchronize activities use the MMS Manufacture Message Specification technology Now it is not really used because the Ethernet technology replaced it e document 16 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 44 102 11 1 2 PROFIBUS DP Decentralized Peripheral Used for applications type master slave with device management and a very short access time Speeds are until 12 Mbits s and more than 90 of PROFIBUS applications are DP type e document 16 11 1 3 PROFIBUS PA Process Automation PROFIBUS PA is used to control applications of process with a communication with actuators or sensors The alimentation and the signal are on only one wire e document 16 The Figure
9. 59 shows the three PROFIBUS variant in a process Cell level access time lt 100ms Field level access time lt 10ms eraran riii Sensor actuator level access time lt 10ms Sensor Valve CNC Computerized Numerical Control HMI Huma Machine Interface Figure 59 Classification of PROFIBUS Networks e document 16 The PROFIBUS network allows to have e Direct control of the frequency converter Run Stop Speed reference Fault reset e Full access to all parameters e Monitor status Output frequency Output current As the coiler drive PROFIBUS network used is the DP variant only this variant will be introduce here e document 16 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 45 102 11 2 PROFIBUS DP Layer The specification of the PROFIBUS DP standard cover layers 1 and 2 in the Model OSI Open System Interconnection The layer 1 is the physical layer characterizes supports of transmission three standard are used RS485 optic fibber OF and CEI 61159 2 The layer 2 is the data link layer it calls FDL for Field bus Data Link layer and it characterizes access procedures transmission services and telegram structures PROBIFUS DP is based on a semi duplex asynchronous gap free synchronization The connection is on only one wire positives point is to decrease the length easy to add stations and works even if a station is out of order Nega
10. DP interfaces for the connection of field devices with more complex technical functions There are two types of PROFIBUS DP interfaces in SIMATIC 57 300 The first type is to have DP interfaces integrated on the CPUs This is that configuration that is chosen for the coiler drive the CPU used is the CPU 315 2DP The other type of interfaces is to use a Plug in DP interfaces through an Interface Module IM or a Communication Processor CP Decentralization with PROFIBUS DP 2000 With the CPU 315 2 DP it is possible to choose between master or slave function It can be operate both as DP master or as DP slave In the coiler drive process the PLC is of course the master In the Table 4 it is shown the technical data of the integrated PROFIBUS DP CPU 315 2 DP interface Decentralization with PROFIBUS DP 2000 Table 4 Technical data of the integrated PROFIBUS DP interfaces Decentralization with PROFIBUS DP 2000 48 Module CPU 315 2 DP MILFB 6ES7 315 2AF03 0AB0 Number of interfaces 2 1st interface for MPI only Operating mode DP master DP slave Baud rates Kbit sec 9 6 to 12 000 9 6 to 12 000 Max number of DP slaves 64 Max number of modules 512 total 32 Input bytes per slave 244 max Output bytes per slaves 244 max Input bytes as slave 244 max Output bytes as slave 244 max Consistent data modules 32 bytes max 32 bytes max Usable input area 1 Kbyte Usable output area 1 Kbyte Max parameter data per slave 244 byte
11. Table 3 Pin assignment of the 9 pin sub D plug connector Decentralization with PROFIBUS DP 2000 18 View Pin No Signal Name Designation 1 SHIELD Shield or function ground 2 M24 Ground of the 24V output voltage 3 RxD7TxD P Receiving sending data plus B line 4 CNTR P Signal for direction control P 5 DGND Data reference potential ground 6 VP Supply voltage Plus 24V Plus of the output voltage 7 P24 auxiliary power Receiving sending data Minus A 8 RxD7TxD N line 9 CNTR N Signal for direction control N TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 47 102 11 2 3 Field bus Data Link Layer 2 Telegram formats as seen on Figure 62 provide a high degree of transmission security Format with fixed information field length i A A p Leneth of the SD1 l DA SA FC FCS ED EER i S Single Sing ecl acter ol ly used for acknowledgment Charact L 3 fixed SDI Stat Start byte distinguishes between different telegram format Format with fixed information field length with data Delimiter to SD4 re s ere cn LE LEr LEngth eneth byte indicates the length of the inifermation fic SD3 DA SA FC Data unit FCS ED r LEngth Length byte ir licate the length of the iniformation field n telegrams Of variable length z DA Destination Address Destination address byte indicates which station is to receive the messagi L 11 fixed l inat
12. University of Applied Sciences Departement of electrical engineering Introduction 1 Introduction The aim of this thesis is to introduce the work done for the coiler drive In the past the coiler drive received customizations The first one was to manage the process with two frequency converters it was done by Jesus Macarro Galindo in 2004 final thesis Frequency converters controlled by PC in coiler drive process The second one was to add a regulation by feedback system That work was done in 2005 by Bravo Zarza Jacinto and Garcia Garcia Jos Luis final thesis Design of coiler drive process and their regulation by feedback system Since more customizations were done for example old frequency converters Vacon CX were replaced by two more recent Vacon NXP and a programmable logic controller Siemens Simatic 57 300 was added This new installation more sophisticated allows to manage the process with an human machine interface HMI through a PROFIBUS network A HMI allows to have a view on every data in the process It is useful to do practical experiences to change the speed the torque or the tension in the nylon web for example With this installation students are able to take some measurements and to see how works a process managed by an HMI through a PROFIBUS network Therefore tasks were to do the design and the creation of an HMI and to configure all the settings for the PROFIBUS network To explain al
13. for his help during my PROFIBUS addresses problem Tampere Finland June 2010 Crivelli Manuel TAMK University of Applied Sciences Departement of electrical engineering Final thesis Table of Contents i OCHO g Ren pepRn sree errr eer re cen ern rent cer Ri errre net eaeret rer yy eee eee ere reer 1 2 NAN VD Tl i ota ate catego A eee eee 2 ZA COMS tO Tirs A E N E N toes 3 22 MOU VAD NCA NO Neser ae T T E TOE 3 Door Winder AG NING seansen a a acetates 4 2 CONerdiveprescmta NO esise E S ia 6 4 Electrice 0416 ko soinean a a a a 7 PE CON UO a E a O T 7 42 Funcional principle messene A ere tere teen trey 8 43 MGEMETAL SP SCiP iCal LOIS coca stesso A N 9 Ao NNO aes ctanatcet cheated tig caer talon E E easiest ctotnake 9 432 PCE COMES lca cese tis o e e e Maza itceea eee nig 9 4 4 Electric motor in the Coiler Diy excise ceostet cach cece taatesieeecth cee stet acta stecieateatenaceeatee 10 2 Progucncy CONVEO aiina a E A N 11 Del Eleccion E A E A 11 SLE RECE e Or een eee nee ror Orc ree eerie ar ee tye ere ee ee 12 5k22 Iniermedidie cre onea oreeet ie nee tere tre erase eer te eee 12 a 6 01 2 Ga CIRO Re CT ORT eT DIOS eee MTT One eer err OTST eT Tare 12 SLA Controland reeulation crt uit xcs sis tescics esse sedate a seine 12 52 PRCQUEHICY converter OVES snini a a a aden 13 99 Frequency converter mthe Coler Dive erisograans e a EN 14 TAMK University of Applied Sciences Departement of electrical en
14. independent outputs e document 4 5 TAMK University of Applied Sciences Departement of electrical engineering PLC page 23 102 6 9 PLC in the coiler drive Brand SIEMENS s n Figure 29 Simatic S7 300 Series SIMATIC S7 300 SM321 SM322 DI 32xDC 24V DO 32xDC 24V 0 5A 321 1BLO00 OAAO 322 1 BLO0 OAAO Power Supply PS 307 5A DC 24V Central processing unit CPU 315 2 DP Signal modules SM 321 DI 32xDC 24V and 322 DO 32xDC 24V 0 5A TAMK University of Applied Sciences Departement of electrical engineering Sensors page 24 102 7 Sensors in the coiler drive Two main sensors are present in the coiler drive process a position sensor to measure the tension of the nylon web and infrared sensor to measure the speed of the nylon web 7 1 Tension sensor Its task is to measure the tension in the nylon web For that this sensor is divided in two parts The first one is the inductive linear displacement transducer The inductive displacement transducer is made by two coils which are encapsulated in a stainless steel cylinder and it contains a metal plunger core causes opposing changes of inductance when it is displaced through the center of the coils The second part is the transducer module It has been designed to demodulate the measuring signal to obtain a DC output signal proportional to the measuring stroke of the inductive linear displacement transducer Zarza amp Garcia 2005 O
15. logo and the Appearance windows will be open In properties tab you can modify the size and other settings Wir exible Advancec zile tive int r Project Eit Wew inet Eoma Faepises Options Window tieip wA PR Y Be HM E Ra H f H Speed web ai 5 OrxR English United Stasies m a ee sae ee Fre ku Popat c a E E ae Boden WWE fibi Auntee ol 2A Saee a a n emolste orele TJ Conmot_Panet Graphics O Motor EJ We feble image Folders a TAMPEREEN E E My Image Foke Start Now ind C trend AMMATTIKORKEAKOULU n Coler dia e Commurscabon a Tage Ss Connectors A Cycles jy Alam Management g E Ansiog Aam fe cb fit EA Dircrete Alame dk amp Settings designationjpg DECNISILJPG DSCHL R64 eleil mot DR Recpes copie og a Mp Hiatoncai Dat a By Soips if Uis 5 2 Repat Tet and Graphics List ka Runtime U ner Adewrestrahon HMLipg mastersiave Modicon pic interni D Devoe Settings M340jpa copiaiog RJ Language Settrg D Prci Languages i Eny i s Graphics cz Project Tent pic_vorking IPG profibws_bits s7 200 234jp9 57 200Jng 2 Structuser Vernon Management SEW o esens vecon E sew 9S Siemens De Vacon JOG sacon NPXJPG gt O mE Vacon_xs 26 cage Induction 600px Variat x Acpomarce Calon Porter det Sexe we B00px Cend BOOEx Mylan Rotatingtiel ranr png l Figure 14 WinCC drag and drop the picture TAMK University of Applied
16. m s acc deace m s Tensionweb N Figure 50 HMI Main screen First click on the button to energize the coiler drive Make sure that the coiler drive is properly connected with the power supply If everything is right the red LED control becomes green both frequency converter turn on and both electric engines are energized After that set the parameters in the Step 1 Figure 51 Speed web acc deacc and Tension web Click on the 0 and enter the correct values TAMK University of Applied Sciences Departement of electrical engineering HMI coiler drive page 40 102 step 1 Step 2 Speed web m s Wind Bernini acc deace m s Tension web CO WN Figure 51 HMI Step 1 Figure 52 HMI Step 2 Then the second step is to choose the wind mode wind or unwind click on the selector to change the mode Figure 52 When the step 1 and 2 are done the PLC has all the settings and parameters to manage the coiler drive properly Therefore in step 3 motor brakes can be turn off by clicking switch 1 and 2 Figure 53 Then the motor control LEDs become green Figure 54 Step 3 Break motor 1 ON FPL Jorr Break motor 2 ONL Jorr Figure 53 HMI Step 3 Figure 54 HMI Motor control LED Before clicking on the green button in Step 4 check if the coils are really free to turn and if everything is ready The coiler drive has to be free of tools and other kind of objects that could create
17. motor is connected to the core of the roll and the other to the layon roller Center surface winders are complicated costly and until recently fairly rare Good amp Roisum 2008 TAMK University of Applied Sciences Departement of electrical engineering Coiler drive presentation page 6 95 3 Coiler drive presentation Coiler drive is a kind of winder machine used in different industries such as paper textile and even metal industry This machine enables to roll different materials Figure 6 Paper Tissue Metal sheet Wire Figure 6 Material rollable by a coiler drive The coiler drive used in Figure 7 is a didactic machine It winds the nylon web from one coil to the other The purpose of this machine is to familiarize the student with the process however industrialist coiler drives are really more sophisticated Figure 7 The coiler drive The different elements are showed in the Figure 8 Programm able Logic Controller Frequency converter Electric Sensors motor Coils and Nylon web Software Figure 8 The different elements in the coiler drive TAMK University of Applied Sciences Departement of electrical engineering Electric motor page 7 102 4 Electric motor The electric motor used in the coiler drive is an asynchronous squirrel cage geared motor Today this type of motor is the cheapest and the most used in the industry The motor s brand is SEW EURODRIV
18. page 26 102 8 Software for the frequency converter In this chapter the two different software employed for the frequency converter will be introduce The purpose is to show you witch software is used with which elements and what are their functions Basic functions will be introduced more information about software can be found in the online manual on the constructor s websitet 8 1 NC Load Two software from Vacon are used to manage the frequency converter NC Load and NC Drive The Vacon NC Load Figure 32 is a basic tool for downloading System software Option card Applicat software into EE the frequency hel converter Vacon NC Load Frequency converter Figure 32 Vacon NC Load software VACON 2010 1 Vacon website www vacon com TAMK University of Applied Sciences Departement of electrical engineering Software page 27 102 The graphical user interface Figure 33 provides an easy point and click selection of applications to be downloaded ComPort Baudrate Drive Options Help Application File Browse Exit Com 1 Baudrate 57600 Figure 33 NC Load main window 8 2 NC Drive The Vacon NC Drive Figure 34 is the commissioning and monitoring tool It allows to e Download and upload parameters set between the drive and the PC e Compare parameters set e Change the active application e Save and print parameters and service reports to file or paper e Control the dr
19. some damages After this checking click on the green button to start the process Arrows appears on the web to show the web direction Figure 55 Data from the two frequency converters n T and P are collected through the PROFIBUS network The TAMK University of Applied Sciences Departement of electrical engineering HMI coiler drive page 41 102 same thing for the speed sensor and the tension sensor data This print screen is done with the simulator and that is why these parameters show the default value 0 Oo ms Tension senso Oo N Break motor 1 cred Oper Break motor 2 Chef On Figure 55 HMI Process running It is possible to change parameters even if the coiler drive process is on For the tension web for example the button can be drag to rise or to decrease the tension in the web Other screens are done to show more information On the left side in the navigation menu click on the third icon to activate the trend screen Figure 56 Tension web 40 N Tension sensor 50 N 10 27 09 AM 10 27 34 AM 10 27 59 AM 10 28 24 AM 10 28 49 AM 6 4 2010 6 4 2010 6 4 2010 6 4 2010 6 4 2010 Ee BAZ ZM ee 282 eae Speed web 10 m s Speed sensor 8 m s E 2 ee ee ee 10 27 09 AM 10 27 34 AM 10 27 59 AM 10 28 24 AM 10 28 49 AM 6 4 2010 6 4 2010 6 4 2010 6 4 2010 6 4 2010 TET 2AT Se ee 129 g Figure 56 HMI Trend screen This screen shows four different trends as e Tension web in gr
20. 2 102 Appendix 5 Programming and configuring the PROFIBUS DP network First the STEP 7 configuration and programming for a PROFIBUS network will be introduced Secondly the cable installation and connections will be seeing and finally the configuration for the frequency converter will be explained PROFIBUS Network STEP 7 Settings We assume that the STEP 7 project and all the others specifications like hardware configuration are already done We start in the main project screen To add a PROFIBUS network right click to open the shortcut menu and select Insert New Object Figure 1 RI SIMATIC Manager Coiler Drive C Documents and Settings abra Coiler_D EP File Edit Insert PLC View Options Window Help be les g 25 25 ess SH lt Mo Filter gt Jy 32 amp Coller Drive Insert New Object SIMATIC 400 Station PLT SIMATIC 300 Station SIMATIC H Station SIMATIC PC Station SIMATIC HMI Station Other Station SIMATIC 55 PaPe Object Properties Alt Return MPI PROFIBUS Industrial Ethernet FTP 57 Program My Program Figure 1 SIMATIC Manager Insert New Object Next step select the object PROFIBUS and right click to open the shortcut menu and then select Open Object Figure 2 to call the graphic configuration tool NetPro TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network config page 93 102 J SIMATIC Manager Coile
21. 6 Specifications for function SFC 14 and SFC15 SFCs for Distributed I Os 15 5 Reading Consistent Data of a DP Standard Slave with SFC 14 DPRD_DAT Data Consistency Refer to the section Overview of S7 Communication and S7 Basic Communication Data consistency Purpose of SFC 14 You require SFC 14 DPRD_DAT because you can only read out a maximum of four continuous bytes using load instructions that access the I Os or the process image input table Description With SFC 14 DPRD_DAT read consistent data of a DP standard slave you read the consistent data of a DP standard slave with the maximum length being fixed for each specific CPU You will find the maximum length in the technical data of your CPU If no error occurred during the data transfer the data that have been read are entered in the destination area identified by RECORD The destination area must have the same length as configured for the selected module with STEP 7 If you read from a DP standard slave with a modular design or with several DP identifiers you can only access the data of one module DP identifier per SFC 14 call specifying the configured start address LADDR INPUT WORD Configured start address from the area of the module from which the data will be read Note Addresses have to be entered in exadecimal format For example diagnostic address 100 means LADDR W 16 64 RET_VAL OUTPUT INT IQ M D L If an error occurs while the funct
22. 7 and 8 that give through one example a lot of information like how to create a project or an interface multilingual At the end of these two manuals it is possible to create the first interface But it is still very difficult to really know the straight way to do some specific task A lot of practice is needed to really be able to work efficiently Some communication problems appeared when some tests were done with the PLC Indeed there are two possibilities to test the interface with the simulator or with the launcher If the way with simulator is chosen the PC plays the role of the PLC and of course it is not possible to change parameters with the real PLC So to test with the PLC the way with the launcher has to be taken TAMK University of Applied Sciences Departement of electrical engineering Final conclusion page 66 102 12 3 The work on the PROFIBUS network This task was the most difficult part for this thesis First of all Siemens gives some basic information about PROFIBUS but it is very difficult to really find very useful information Siemens Company organizes many training sessions for PROFIBUS so maybe this is why they do not publish a lot of information Luckily the book Decentralization with PROFIBUS DP found in the TAMK library describes all the steps to configure the PROFIBUS network with STEP 7 proberly It was a very useful book with many examples and a lot of details The PLC configuration for th
23. C Peme Ai Connection Datatype address comment Alim_process Connection_1 Bool O41 process alimentation Break 1 Connection 1 Bool Q45 break motor 1 Break Connection_1 Bool 4 6 break motor 2 Current_Language lt Tnternal tag gt Int lt No address gt motor_1 speed Connection_1 Int IW 4 speed motor 1 motor speed Connection_1 Int IW 6 speed motor 2 programme Connection_1 Bool 114 0 choose betwen wind or rewind Speed sensor Tonnection_1 Int Iw 12 speed from the speed sensor Speed web Connection_1 Int Iw 10 speed s setting Start Connection_1 Bool 12 0 start the process Stop Connection_1 Bool 12 2 stop the process Tension_sensor Connection _1 Ink Iw G value From the tension sensor Tension web Connection 1 Ink I 2 Figure 9 WinCC Tags After all these steps the configuration is done Now it is possible to start the creation of the interface TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 87 102 Interface creation Template First the template has to be defined Template is the basic screen in every new screen done the template will be applied In the Template there are these kinds of object Navigation menu Logo Project Title Background Date and time Other Here the template for the Coiler Drive on Figure 10 Figure 10 WinCC Template coiler drive TAMK University of Applied Sciences Departement of electrical enginee
24. Documentation gt English The online help F1 on a component if it has forgotten the details of its entries for example is really useful TAMK University of Applied Sciences Departement of electrical engineering Software page 35 102 9 2 WinCC After a short introduction of Human Machine Interface it will be explained in general the different notions about the WinCC software For more information about the HMI in the coiler drive the file 9 2 1 HMI introduction Before to explain what exactly WinCC is let s see what mean an HMI Human Machine Interface A HMI system represents the interface between man operator and process machine plant On the Figure 46 the device OP 77b is used with an HMI program o n b r s tee 5 bsa hd Figure 46 Process with an HMI device e document 6 The PLC is the actual unit which controls the process Hence there is an interface between the operator and WinCC at the HMI device and an interface between WinCC and the PLC An HMI system assumes the following tasks e document 6 Process visualization The process is visualized on the HMI device The screen on the HMI device is updated very often almost dynamically Operator control of the process The operator can control the process by means of the graphical user interface GUI The operator can preset reference values for the controls or start a motor for example TAMK University of App
25. E a German manufacturing company Founded in 1937 it is now an international organization that manufactures geared motors frequency inverters and servo drives It employs over 11 000 people worldwide with annual sales in excess of 2 billions 2008 EURODRIVE 2010 4 1 Construction The basic structure of an asynchronous motor is schematically illustrated in Figure 9 There are two mechanically independent parts the rotor and the stator Figure 9 Asynchronous squirrel cage motor Amin 2001 6 Both of them are separated from each other by a narrow air gap that allows the former to rotate freely inside the stator The magnetic circuit of the rotor and stator consists of iron laminations The stator and rotor yokes close the motor s magnetic circuit Windings are fixed in slots distributed regularly around the air gap in both the rotor and the stator Amin 2001 In the stator there are pre fabricated sections which contained several turns of elementary conductors cooper lodge within the various slots regularly situated around the stator Sections are linked together in order to constitute a number of independent circuit called phases Most industrial asynchronous motor have three identical symmetrical phases spaced by an angle of 21 3 radian Squirrel cage is made of aluminium or cooper bars Amin 2001 TAMK University of Applied Sciences Departement of electrical engineering The bars lodge in the rotor slots an
26. Operative cycle e document 16 The instruction execution is done in order of their storage in program memory incrementing a counter computer ordinal initially containing the start address of memory It allows the transition to the next instruction unless a skip forward can moved further away at an address higher are breaching not a set of instructions e document 16 TAMK University of Applied Sciences Departement of electrical engineering PLC page 21 102 6 8 Language By default four languages can be used The choice depends of the application and also preferences programmer The four languages are 6 8 1 Instruction List IL It is a textual language a kind of assembly language used to programme microprocessor An instruction starts a line and in this line there is an operator with one or more operand For example in Table 2 the operator LD is used to load a value ST to save this value e document 4 5 Table 2 Example of IL language e document 4 Label Operator Operand Comment a ns 0 r5 tart FAB2 ST MX11 stage 2 This language is not convenient because it is difficult to have a graphic analyse and the programming is complex This language is not often used e document 4 5 6 8 2 Structural Text STL The Structural Text language is an informatics language It presents some analogies with the Pascal language It uses expressions ordered assembly of operator and operand w
27. Sciences Departement of electrical engineering Button WinCC Projects page 90 102 In the template it is useful to create a navigation menu It allows to change screen automatically when a button is clicked To explain what are the steps to create a button the trend button will be choose as an example First click on the Simple Objects menu Figure 15 Choose the object Button and drag and drop in the work area Cj Sart Tools Sik 2 Simple Objects Une o Polytine cq Polygon Rectangk A TextField Dl 10 Field Sy Oate Time Field Ey Graphic 10 Field Symbolic 10 Field Button mode Text Ten Text O Tent bet Graphic Text opp Text Iewicible a Hotkey Tea on Hotkey Nore 4 Figure 15 WinCC Drag and drop button Now we have to insert a picture on the button In WinCC a picture is a graphic element therefore choose Graphic Figure 16 in the Button mode and in the Graphic OFF field choose the right picture then valid with the set button lt j Template_Button Button iler copi electical_motor E stop General gt Properties p Animations p Events Flag of France Flag of United Ki T Graphic_1 Button mode i Graphic Graphic _2 Text Graphic Graphic Graphic OFF Invisible Graphic ON Graphic OFF Hotkey Hotkey None Figure 16 WinCC
28. System error with external DP interface module gt Z System Software for S7 300 400 System and Standard Functions 15 18 A5E00069892 02 TAMK University of Applied Sciences Departement of electrical engineering SFC 14 and SFC 15 functions page 101 102 SFCs for Distributed I Os 15 6 Writing Consistent Data to a DP Standard Slave with SFC 15 DPWR_DAT Data Consistency Refer to the section Overview of S7 Communication and S7 Basic Communication Data consistency Purpose of SFC 15 You require SFC 15 DPWR_DAT because you can only write a maximum of four continuous bytes using the transfer instructions that access the I Os or the process image input table Description With SFC 15 DPWR_DAT write consistent data to a DP standard slave you transfer the data in RECORD consistently to the addressed DP standard slave The maximum length of the data to be transferred is fixed for each specific CPU You will find this information in the technical data for your CPU The data is transferred synchronously in other words on completion of the SFC the write job is also completed The source area must have the same length as you configured for the selected module with STEP 7 If the DP standard slave has a modular design you can only access one module of the DP slave Declaration LADDR INPUT WORD 1 Q M D L Configured start address from the process constant image output area of the module to which the d
29. T_VAL MW200 The last parameter RECORD specifies where data have to be saved The best way is to save data in a table Therefore we have to create a table with eight bytes a table is called Data Block in STEP 7 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 53 102 To create a Data Block in SIMATIC Manager in the Blocks tab a right click in the middle of the screen then Insert New Object and Data Block has to be chosen as seen on Figure 66 Insert New Object Organization Block PLC Function Block Function mie Data Block Compare Blocks Data Type Reference Data d Variable Table Check Block Consistency Print Object Properties 4lk Reeturn Special Object Properties Figure 66 STEP 7 Insert Data Block The name has to be changed in DB10 and the then the LAD STL FBD editor double click on the DB10 icon has to be opened Here the data block can be created for that specify a name like in our case Inputdata and the type is ARRAY 1 8 BYTE It means that a table with eight squares is created and the type of the data is BYTE as in the Figure 67 RA LAD STL FBD DB10 Coiler Drive profibus SIMATIC 300 Station CPU 315 2 DP 1 GG File Edit Insert PLC Debug wiew Options Window Help Dao amp ao oo Fy ir DEAR A faaazess name lt idiype initial value coment ee 9 Libraries
30. Tampere University of Applied Sciences Master of engineering Departement of electrical engineering Crivelli Manuel Final thesis Design and creation of an HMI and a PROFIBUS network configuration with a PLC for a coiler drive Thesis supervisor M Sc Lauri Hietalahti TAMK Tampere June 2010 TAMK University of Applied Sciences Departement of electrical engineering Final thesis pagen Writer Crivelli Manuel Thesis Design and creation of an HMI and a PROFIBUS network configuration with a PLC for a coiler drive Number of pages 102 Graduation time June 2010 Thesis supervisor Lauri Hietalahti Commissioned by Tampere University of Applied Sciences Abstract This work is about the design of a user s Human Machine Interface HMI that is used to manage a Coiler Drive The user has to be able to set settings and check data in this HMI The user can for example change the process speed and check the tension of the nylon web of a paper machine Data and parameters set are sending through an industrial field bus PROFIBUS to a Programmable Logic Controller PLC The purpose of this thesis is to explain the process to create an HMI and to configure a PROFIBUS network Different software has been used and they are explained summarily The creation of HMI is very important for the user because it allows the easy entry of settings and furthermore the simple control of a process Today almost every process cont
31. a manufacturer of variable speed AC drives and comes from Finland Founded in 1993 with 13 key employees it is now one of a leading global supplier of AC drive around the world Since 1 200 more people have joined manufacture serving a network of customers and partners all over the world The revenues in 2008 were 293 millions VACON 2010 5 1 Electrical diagram There are four main components in modern frequency converters Figure 15 Figure 15 four main components in modern frequency converter Galindo 2004 Recent frequency converters also contain a stage power factor correction to respect the electromagnetic compatibility standard TAMK University of Applied Sciences Departement of electrical engineering Frequency converter page 12 102 5 1 1 Rectifier The rectifier stage produces direct current which will then be inverted to produce AC of the desired frequency Its purpose is to convert the three phase AC voltage to a pulsating DC voltage Amin 2001 5 1 2 Intermediate circuit There are many kinds of intermediate circuits but three kinds are the most important One kind converts the voltage of the rectifier into a DC current A second type stabilizes the pulsating DC voltage and sends it into the inverter The last type converts a constant DC voltage from the rectifier into a variable value Amin 2001 5 1 3 Inverter The inverter s role is to convert constant DC voltage into an AC voltage and to contr
32. a there is 13 88 hex in decimal we obtain 50 00 that is correct because the maximum frequency is 50 00Hz TAMK University of Applied Sciences Departement of electrical engineering Final conclusion page 65 102 12 Final conclusion To begin let s see in detail the work that has been realized and the problems encountered After that we will see all the improvement that can be done in the future for the coiler drive process 12 1 The work with STEP 7 In a previous work a program was already made with STEP 7 for the coiler drive process It is a small program but enough to start and stop the energy into the coiler drive First of all the task was to learn how this software works Manuals from Siemens were very useful particularly the manuals SIMATIC Working with STEP 7 V5 1 e document 2 that allows a fast understanding of STEP 7 by showing examples There were no big problems to work with STEP 7 The connection between the PC and the PLC worked properly Some mistakes were done eventually but it was easy to fix these with help In STEP 7 the help is very important it should be used because there is a lot of useful information 12 2 The work with WinCC It was harder to understand this software because there were no example s already made Luckily there are two very useful manuals SIMATIC HMI WinCC flexible Getting Started First Time User and SIMATIC HMI WinCC flexible Getting Started Experts e document
33. a of a DP slave device with SFC 14 DPRD_DAT This function has to be used because it is only possible to read a maximum of four continuous bytes using load instructions With the SFC 14 function data can be read with the maximum length fixed for each specific CPU In our case we need to read twelve bytes When the reading starts two possibilities can happen The first one is if no error occurred during the data transfer the data that have been read are entered in the destination area identified by RECORD The second one is if an error occurred during the data transfer the type of error is sent to RET_VAL In the documentation you can find the error information with the error code in the appendix 5 Now let s see how the function has to be configured in STEP 7 e document 12 The Vacon frequency converter is in PPO1 mode It means that eight bytes are for parameter data and four for the process data Therefore it should have two reading function and also two writing functions To create the first reading function for the parameter data in STEP 7 program a new network has to be created in the main block OB1 and in STL language the function SFC 14 has to be called like on the Figure 65 CALL DPRD DAT SFC14 Read Consistent Data of a Standard DP Slave LADDR RET VAL RECORD Figure 65 LAD STL FBD CALL SFC 14 function TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS netwo
34. ains HMI With the HMI the Coiler Drive becomes a complete configurable industrial machine Future steps will be the analysis of the settings for modification deletion or addition Keywords Final thesis Coiler Drive Human Machine Interface PROFIBUS Programmable Logic Controller Frequency converter Siemens Vacon TAMK University of Applied Sciences Departement of electrical engineering Final thesis pagen Tekij Crivelli Manuel Opinn ytety HMI n suunnittelu ja toteutus sek Profibus verkon konfigurointi kelaink ytt varten Sivum r 102 Valmistumisaika Kes kuu 2010 Ty n ohjaaja Lauri Hietalahti Ty n tilaaja Tampereen ammattikorkeakoulu Tiivistelm T ss ty ss suunnitellaan ja toteutetaan ihminen kone rajapintaa Human Machine Interface HMI jota k ytet n kelaink yt n hallintaan K ytt j n on voitava tehd asetuksia ja tarkistaa tietoja taman HMI n avulla K ytt j voi esimerkiksi muuttaa prosessin nopeutta ja tarkistaa paperikoneen nylonverkon kireytt Tiedot ja parametrit l hetet n teollisen kentt v yl n Profibuksen kautta ohjelmoitavan logiikan ohjaimeen Programmable Logic Controller PLC T m n opinn ytety n tarkoituksena on selvitt HMI n suunnitteluprosessia ja Profibus verkon konfigurointia Ty ss on k ytetty erilaisia ohjelmistoja jotka on kuvattu lyhyesti HMI n suunnittelu on sangen t rke k ytt j n kannalta koska se mahdo
35. ata will be written Note Addresses have to be entered in hexadecimal format For example diagnostic address 100 means LADDR W 16 64 RECORD INPUT ANY Source area for the user data to be written This must be exactly as long as you configured for the selected module with STEP 7 Only the BYTE data type is permitted RET_VAL OUTPUT 1 Q M D L If an error occurs while the function is active the return value contains an error code System Software for S7 300 400 System and Standard Functions A5E00069892 02 15 19 TAMK University of Applied Sciences Departement of electrical engineering SFC 14 and SFC 15 functions page 102 102 SFCs for Distributed I Os Error Information System error with external DP interface module 8090 e You have not configured a module for the specified logical base address or e you have ignored the restriction concerning the length of consistent data or e you have not entered the start address in the LADDR parameter in hexadecimal format A type other than BYTE is specified in the ANY reference 8093 No DP module to which you can write consistent data exists at the logical address specified in LADDR 80A1 Access error detected while I O devices were being accessed Slave failure on external DP interface module The length of the specified source area is not identical to the user data length configured with STEP 7 System error with external DP interface module ars System error with ex
36. be 1 500 1 000 750 etc Amin 2001 Another way to change the speed is to vary the frequency f of the stator s current As a result the frequency converters would change not only the frequency f but the tension as well The advantage is to keep the motor in the same magnetic state regardless of the frequency of the stator s current TAMK University of Applied Sciences Departement of electrical engineering Electric motor page 10 102 This way allows to keep the same curve as a function of frequency torque for any frequency of stator current as seen in the Figure 11 and 12 Amin 2001 Constant flux range SPEED 0 500 1000 1500 2000 2500 3000 N tr min Figure 11 Maximum torque Galindo 2004 Figure 12 Torque trend Amin 2001 15 4 4 Electric motor in the Coiler Drive l Figure 13 Unwinder motor Figure 14 Winder motor Designation R27 DT90S4 BMG EV1A Nominal current 2 8 A Nominal power 1 1kW Nominal voltage 400 V Nominal Torque 7 5 N m Power factory cos 0 77 Nominal speed 1400 rpm Efficiency 77 5 TAMK University of Applied Sciences Departement of electrical engineering Frequency converter page 11 102 5 Frequency converter A frequency converter is an electronic device that converts alternating current AC of one frequency usually 50 or 60Hz to an alternating current of another frequency The frequency converter used in this study comes from Vacon brand It is
37. by opening the shortcut menu with a right click on the SIMATIC 300 1 icon and then select Open Object Figure 3 D ae SP ar amp A gi o Ss to te EE SE lt Nofilter gt x gt B ole Dive SGP a Giveeseennh Open Object Ctrl Alt O Cut Ctrl X Copy Ctrl C Delete Del PLC Print e Rename F2 Object Properties Alt Return Figure 3 HW Config Open Object The HW Config module is automatically started and a screen appears which is divided into two horizontal sections At this stage it is still empty because the next step is to configure the hardware for the SIMATIC 300 station The first step is the rack configuration TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 77 102 Li For that in the toolbar click the catalogue button to open the hardware catalogue In this catalogue open the SIMATIC 300 folder and under RACK 300 select Rail Drag and drop the selected rack to the upper left section of the screen Figure 4 Bing fat Profle Standard PROFIBUS DP H PROFIBUS PA 38 PROFINET I0 SIMATIC 300 y C7 0 IM 300 a i SIMATIC 400 SIMATIC HMI Station SIMATIC PC Based Control 300 400 SIMATIC PC Station Figure 4 HW Config Rail Now we have to select a power supply PS open the folder PS 300 and select the PS 307 5A Drag and drop the selected PS in the section
38. d are short circuited at their two ends by the end rings as seen on Figure 10 Figure 10 Squirrel cage Amin 2001 8 4 2 Functional principle The stator s coils are fed by an alternative three phase current and each one produces a magnetic flux whose resultant is a rotating magnetic field This flux cuts the rotor conductors and it induces a current which in turn generate a magnetic field induced in the squirrel cage The rotor s field tends to oppose the flux change Lenz s law and a dynamic effect is created between the two fluxes and causes the rotation of the rotor Amin 2001 The frequency of rotating field is imposed by the frequency of stator current This is called the synchronous speed If you change the frequency of the stator current you change the speed of rotating field and thus the frequency of the rotor The formula for the synchronous speed is nel p Ns in Hz is the frequency of rotation of the rotating fields called the synchronous speed f in Hz is the frequency of stator current AC power frequency p is the number of phase The rotor can never reach the synchronous speed as there would be no change in rotor flux in the conductors This explains the name of this kind of motor asynchronous There are two inconveniences when the motor is started the current is very important in the stator and the torque is low Amin 2001 Electric motor page 8 102 TAMK University of Applied Science
39. d fault finding and error elimination e document 16 In this chapter the design of a programmable logic controller and its interaction with peripherals will be explained 6 1 Introduction In 1968 a group of engineers at General Motors developed the first PLC The company looked for a new device able to replace complex relay control systems The different requirements were shown on the Figure 18 Program changes Simple programming without system intervention Smaller cheaper and more reliable than Simple and low cost corresponding relay maintenance control systems Figure 18 Requirements for the first PLC The development resulted in a system which enabled the simple connections of binary signals With this kind of system it is possible for the first time to plot signals on a screen and to file these in electronic memories e document 16 The task of a PLC is the interconnection of input signals according to a specified program and if the value is true to switch the corresponding output Boolean algebra is the base of all the mathematical operations For example a motor could therefore be switched on or off This I O behaviour is similar to that of a pneumatic switching valve controller or an electromagnetic relay Since the first PLC enormous progresses are made in the development of microelectronics and during the seventies binary I O were finally expanded with the addition of analogue I O TAMK Unive
40. der in the offline window and then download the program to the CPU using the download icon a or the menu command PLC gt Download and then check if everything is downloaded in the online window TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 82 102 Appendix 4 User manual Coiler drive HMI configuration with WinCC Creating a project fl P SIMATIC To start the application double click on the shortcut Win flexible 2006 The WinCC flexible project is opened and it is possible to be guided step by step through the configuration settings for that select Create a new project with the Project Wizard as seen on Figure 1 Project Edit Yiew Insert Format Faceplates Options Window Help D amp ORR Welcome to the WinCC flexible Project Wizard Please select one of the options below e Toleam more about an option move the mouse pointer over it e Click on an option to select it I Options Open the most recently edited project Creates a new WinCC flexible project step by step Select or configure project components such as controls HMI devices Create a new project with the Project screens and libraries in each step Finally the Project Wizard creates izard the new project based on your specifications and opens itin WinCC flexible Open an existing project You can further edit the project in WinCC flexible and change or add to your settings Create an empt
41. e R Regenerative low harmonic AFE Brake chopper 0 No brake chopper 1 Integrated brake chopper EMC emission level EN61800 3 L 2nd environment T For IT networks Enclosure class 2 IP21 Nema 1 cabinet mounted 5 IP54 Nema 12 cabinet mounted Control keypad A standard alpha numeric B no local control keypad F dummy keypad G graphic display Nominal mains voltage 3 phase 5 380 500Vac 6 525 690 Vac Nominal current low overload e g 0460 460A etc Product range NXP TAMK University of Applied Sciences Departement of electrical engineering Designation Vacon NPX page 74 102 Appendix 2 PROFIBUS GSD file Profibus_DP GSD_Revision 1 Vendor_Name Vaasa Control Model_Name Vacon NX Revision 1 1 Ident_Number 0x9500 Protocol_Ident 0 Station_Type 0 FMS_supp 0 Hardware_Release HW1 0 Software_Release SW1 0 9 6_supp 1 19 2_supp l 93 75_supp i 187 5_supp 1 500_supp 1 1 5M_supp 3M_supp 6M_supp 1 12M_supp 1 MaxTsdr_9 6 60 MaxTsdr_19 2 60 MaxTsdr_93 75 60 MaxTsdr_187 5 60 MaxTsdr_500 100 MaxTsdr_1 5M 150 MaxTsdr_3M 250 MaxTsdr_6M 450 MaxTsdr_12M 800 Redundancy 0 Repeater_Ctrl_Sig 0 24V_Pins 0 Implementation_Type SPC3 Freeze_Mode_supp 1 Sync_Mode_supp 1 Auto_Baud_supp 1 Set_Slave_Add_supp 0 Min_Slave_Intervall 6 Modular_Station 1 Max_Module 5 Max_Input_Len 28 Max_Output_Len 28 Ma
42. e complex elements in particular operations on bits such as a flip flop SR Priority release or RS priority engagement POS and NEG for the detection of fronts In the manual CONT S7 other useful functions like meters tempos etc can be founded Generally the program is broken down into several networks and the networks are executed sequentially e document 4 TAMK University of Applied Sciences Departement of electrical engineering Software page 33 102 FBD language Exactly the same than LAD language but the presentation is different as seen in the Figure 41 e document 4 Function Block Diagram FBD Suitable for users from the world of circuit engineering for example Green Lig ht PFF Key 1 FF Ke y 2 PF Figure 41 STEP 7 FBD language e document 4 STL language It is a textual language which is closest to the internal behaviour of the PLC corresponding roughly to the assembler in a computer The system always knows translate LAD FBD or LT but not vice versa The program consists of a sequence of lines Figure 42 each specifying an operation code followed by an operand only one The operand can be an absolute address I 0 3 or a symbol in quotes if symbols were defined e document 4 Statement List STL Suitable for users from the world of computer technology for example A Key_1 A Key a Green Light Figure 42 STEP 7 STL language e document 4
43. e eight bytes are used like Parameter Field and four bytes are used like Process Data Field Parameter Field Process Data Field Figure 82 PPO 1 in Vacon NXP e document 16 The DB10 data block used for reading contains the eight bytes for the Parameter Field and the DB31 data block used for reading contains the four bytes for the Process Data Field Figure 83 Parameter Field Process Data Field PPO 1 DB 10 DB 31 Figure 83 PPO1 with data blocks configuration e document 16 For the writing is the same principle The DB11 data block contains the eight bytes for the Parameter Field and the DB32 data block contains the four bytes for the Process Data Field TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 61 102 11 7 1 Parameter field The size of the parameter field is eight bytes and it is divided into three parts ID Index IND and VALUE Figure 84 VALUE tf Lu m iE 2 in LL D APPLICATION PR Figure 84 Transfer of parameter field e document 16 All the details can be found in the documentation e document 16 here it will be explain only the most important parameters For the ID parameter on the Figure 85 it is shown the two possibilities for reading or for writing Read parameter value Write parameter value Figure 85 ID parameter e document 16 In the first byte r
44. e PROFIBUS network was done without big problems and properly with the help of this book The big problem was about the communication configuration It depends on what kind of devices are used for the coiler drive a frequency converter from Vacon is used On the Vacon website there is one manual about PROFIBUS but it describes the steps for the installation of the field card and the configurations but not for the communication Many tries addresses modified direct communication etc were done to send data through the PROFIBUS into the frequency converter But without success and there was the error code number 80B1 see appendix 5 in the reading and writing function The configuration was right because the LED control on the PROFIBUS field card in the frequency converter and on the PLC show that everything worked The problem came therefore from the communication Some e mails were sent to Vacon company to identify the exact location of the problem The field bus team from Vacon checked the coiler drive STEP 7 project The mistake was to send a frame of twelve bytes in one data block The right way was to send two frames the first frame with eight bytes Parameter Field and the second frame with four bytes Process field Otherwise everything was right in the configuration and in the program With this information some runs were tried and finally it was possible to read and write data through the PROFIBUS network Nevertheless one problem
45. e control elements Bk WinCC flexible 2005 Advanced Project hmi Project Edit View Insert Format Faceplates Options Window Help ea New MO Bem English United States lee OP77B_Mixing wee Device_1 OP 77B 8 Screens Add Screen C Template C Date and Time Screen C Info Screen C Language Screen C Operating Mode Screen C Project Info 1 Screen reen ystem Screen Pig Communication gt General Tags gt Properties 57 Connections lt Animations Cycles Evos iz Alarm Management BB Analog Alarms Ne BS Discrete Alarms Use ten Oy Settings Bj Recipes Backgrounc br Reports E te Text and Graphics Lists Ez Tig Runtime User Administration 2 Device Settinas 2 kt Simple Objects No libraries opened Use the context menu thetoolbar or drop objects hereto create oropen libraries Drop any objecthere to ij delete it Figure 48 WinCC Main screen TAMK University of Applied Sciences Departement of electrical engineering HMI coiler drive page 39 102 10 HMI created for the coiler drive The first screen in the human machine interface is the start screen Figure 49 COILER DRIVE Figure 49 HMI Start screen It allows to choose the language and gives a view of the coiler drive Choose the language with a left click on the flag and then the main screen will be opened Figure 50 Step 1 Speed web
46. eading 10 or writing 20 has to be chosen and in the second byte the ID parameter has to be set in hexadecimal format The ID number of each parameter can be found in the Vacon documentation or with NC Drive The Index IND parameter is not in use for our configuration The Value parameter shows the value of the data chosen speed temperature etc TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 62 102 Two bytes are used for the value as shown on Figure 86 ID IND VALUE a a L Data word 1 HIGH Data word LOW byte U byte llita ey Ac e Figure 86 Data value e document 16 In writing mode the data to be written is placed in the field Data word 2 and in reading mode the answer is in the field Data word 2 Data word 1 is normally Zero 11 7 2 Process field The process data field is used to control in writing the motor run stop reset etc two bytes CW CW for Control Word In reading it used to read quick actual values output frequency output current etc Figure 87 Profibus Board i Lu H gn lt wo oo L i APPLICATION Actual Value 1 Figure 87 Transfer of process field e document 16 The size of the field is four bytes in PPO1 mode In our case the use of process data field is to start and stop via the Control Word written by the Master and to set the rotating speed with Reference
47. ean tsseitios quien redstcsavensteanediaien 48 to PFPROPBUS DP in SUVA IC S Y eN erur tn Bees beeches altcessenesath ates auuetatuins 49 11 3 1 Generic Station Description GSD fileSuisnsroii inion 50 TAMK University of Applied Sciences Departement of electrical engineering Final thesis 1L4 PROFIBUS network STEP 7 pro craic wists sesiessancd ceu cases e a A 51 11 4 1 Reading data of a DP slave device with SFC 14 DPRD_DAT 51 11 4 2 Writing data of a DP slave device with SFC 15 DPWR_DAT eec 54 TES Cable and connector cont o urato Nksas ine EE E the setueemes ude 57 11 6 Frequency converter Vacon NXP configuration eesseseeseereeerrerrrerrerrerrrrrresrees 9 11 7 Reading and writing communication esseeeeeeseessesserssesresresrrsrsresresestesresesresreseses 60 ILZ Parameter Geld eeren i a E a OE EA 61 LEA Procee TEE EER E teatectaee eae 62 11 8 Example of data exchange through the PROFIBUS network esseere 63 T FinalconciisioNeoraiin ainen a A A N 65 2L Whework with SEER Zee A ed aieceiicsatch tudes ust tae 65 122 TIS Wr Ke WAVIN C eano aa A soars sua dluanet baled aatametuaaris 65 12 3 The work onthe PROFIBUS DEWO ke ais svecessseastariosatesvcsatvatiordisntecneieatieatsietnnniees 66 TDA NVA AS GNU aoc chassis eae c sce ce aadata seu a scnatatascaen te 67 TD BvD OSA PAY arae E E 68 1 4 2 01 gO LG k pre Re ND rer a eter trees e Prmerr Feng ser errr ree ar Mrre rn Teo ty 72 TAMK
48. easily integrated into an industrial control system and easily used in all their intended functions EN 61131 1 norm TAMK University of Applied Sciences Departement of electrical engineering PLC page 17 102 A programmable logic controller is therefore nothing more than a computer made specifically for certain control tasks The Figure 20 shows system components of a PLC PLC Program e Central control unit i Sensors i Actuators Figure 20 System components of a PLC e document 16 Input module Output module The input module converts incoming signals into signals which can be processed by the PLC It passes these to the central control unit The output module performs the reverse task this converts the PLC signals into signals suitable for the actuators The central control unit process signals in accordance with the program stored in the memory The program of a PLC can be created in various languages Figure 21 as such Function Instruction aa Structural Block List IL LAD Text ST KAN Figure 21 Languages Other special languages are also available like Grafcet language for example Most frequently in industry modular PLCs are used They may be configured individually and the modules required for practical applications are inserted in a rack Individual modules are linked via a bus system TAMK University of Applied Sciences Departement of electrical engineering PLC page 18 102
49. ec vices acuchen wecuec E gen nacoees 28 91 2 Hardware connie tation itssissermndineie yetimusseieiesetn tinier iene 31 Dealer LNG UOC aN sss si E dia peatey iene E E 32 Sie Wransfer tothe PUC rasmini a O 33 DANS More HEPS 5 site tetescs sac r ced ataeennaceaareeaeeictaseuseeceaaees 34 22 NN MN eset ce ast ae se acento ad a nt want nctiacegea ut nites bast one sae ad een aalananddeent nae teas 35 921 AVM OC UCHOM ss csceorecat casa vince ectahs T 35 O22 JderesemtationvOr WNE Caserne teeta citua cl aizactau T 36 De NCU COU e a E E A E 37 TO FIMI created tor the coler div estas team escininacetchamasescanteciansenesiniuarsubenuhensaabet aus 39 el Pied oUon Olin tacaca teanaicnet ov aseaecceptagainateanstatanarasatns acd aptagasente aa seen acatesaine ka ouuaesandueatas 43 LEI Toda u16 qmepereemereremmreeeee meer srr teen Crarrmna ere a 43 11 1 1 PROFIBUS FMS Field Message Specification ce eeeeseeseeeseeseeeneeeees 43 11 1 2 PROFIBUS DP Decentralized Peripheral ee eeeeseeeneceeeeeeeeeeeees 44 11 13 PROFIBUS PA Process Automation eesceescccesseeceseeceeeeeeeseeeeseeeeeeeess 44 TEZ PROFIBUS DPR ay er aeran cans cases ca hateretasch sh gard eons eat ec sae teesaeenetetd 45 V2 8 iPhysical ayer layer iorn e haat cuca annua A 45 TZ USC OMMECC HO Mis eseat tea tveesecesechedandasheasducnbe aE 46 TL29 Field Dus Data Link Layer 2 jesica a 47 124 Bus Access COM Oheareccdescsseeestcas tessivtnsasiennzadaoisnsest b
50. ed to 4 06 2010 Available documentation package order number 6ZB5370 1CM03 0BA2 8 Overview to SIMATIC HMI WinCC flexible Getting Started Experts pdf file referred to 4 06 2010 Available documentation package order number 6ZB5370 1CM03 0BA2 TAMK University of Applied Sciences Departement of electrical engineering Bibliography page 70 102 Manual Vacon 9 Overview to user s manual nxs p frequency converters pdf file referred to 4 06 2010 Available http www vacon com Default aspx id 450403 amp FileView 462792 10 Overview to Frequency Converter User s manual Five in One application manual pdf file referred to 4 06 2010 Available http www vacon com Default aspx id 450403 amp File View 462794 Manual PROFIBUS 11 Overview to User s manual Nx frequency converters PROFIBUS DP OPTION BOARD pdf file referred to 4 06 2010 Available http www vacon com Default aspx id 450403 amp File View 477110 12 Overview to Configuration of S7 300 with CPU315 2 DP as PROFIBUS DP Master pdf file referred to 4 06 2010 Available http www hilscher com 13 Overview to SIMATIC NET S7 CPs for PROFIBUS Manual pdf file referred to 4 06 2010 Available documentation package order number C79000 G8976 C154 14 Overview to R seau Profibus pdf file referred to 4 06 2010 Available http www techniques ingenieur fr book s8160 reseau profibus html TAMK University o
51. een e Tension sensor yellow e Speed web orange e Speed sensor red It is possible to stop the trends to do some measurements TAMK University of Applied Sciences Departement of electrical engineering HMI coiler drive page 42 102 The last screen is done to show all the available information through the PROFIBUS network about both electric motors Figure 57 Motor 2 Temperature 0 Figure 57 HMI Electric motor screen To stop the coiler drive process push on the red button and close the two brakes with the switches in step 3 For every screen it is possible to change the language between English and Finnish by clicking on the flag on the top left of the navigation menu TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 43 102 11 Field bus solution The choice was to use a PROFIBUS network PROFIBUS means PROcess Fleld BUS and it is a field bus based on a shielded twisted pair or an optical network using fibber optic cable Using industrial field bus technology considerable savings can be made particularly in the mechanical installation fitting and wiring of the plant equipment due to reduce cabling for distributed I O devices e document 16 11 1 Introduction In 1987 the German industry has therefore initiated the PROFIBUS cooperative project The regulation and norms developed by this body were documented in the German norm DIN 19245 Since 1996
52. ering in the LADDR parameter LADDR W 16 100 In the RECORD parameter the source area for the user data to be written has to be specified The best way is like for the reading function is to create a new data block The procedure is exactly the same than for SFC 14 function only two things are different the name of the bloc DB11 and the name of the table Outputdata as seen on the Figure 72 HS LAD STLIFBD DB11 Coiler Drive profibus SIMATIC 300 Station CPU 315 2 DP 1 File Edit Insert PLO Debug View Options Window Help De gt S e o Ot ho Ss a lt gt a address Name Type Initial value comment eee ee ee outputdata farray 1 8 O O ere FO emp_sreucr Figure 72 LAD STL FBD DB11 configuration W Libraries eal TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 56 102 This new data block will be send trough the PROFIBUS network and data will be written in the frequency converter RECORD DB11 Outputdata Last step is to set a memory word for the RET_VAL parameter In our case we choose the M W202 RET_VAL MW202 Finally here the function Figure 73 with the right parameters CALL DPWR DAT SPC15 Write Consistent Data to a Standard DP Slave LADDR wW 16 100 RECORD DB11 Outputdata P HDB11 DBEO 0 RET VAL MWz02 NOP 0 Figure 73 SFC15 parameter data function configured For t
53. ess This parameter is used to optimize bus access control token management for multi master bus configuration With a mono master PROFIBUS DP configuration don t change the default setting of 126 for this parameter Transmission Rate The transmission speed you select here will apply to the entire PROFIBUS subnet This means that all stations also called nodes which are used must support the selected baud rate Profile Each bus profile contains a set of PROFIBUS bus parameters In our case we are in a mono master configuration so we have to choose DP profile Option button opens a box where you can run PROFIBUS DP in the Constant Bus Cycle mode Bus parameter button provides access to the bus parameters calculated by STEP 7 Confirm the suggest settings default settings for the example project with OK The next step is to configure the DP Slaves in the HW Config For this select Simatic 300 station and right click to open the shortcut menu Select the command Open Object Figure 5 i NetPro Coiler_Drive Network C Program Files s proj Coiler 1 SY Network Edit Insert PLC View Options Window Help are q amp FB a a S l hk Open Object Ctrl Alt O Copy Ctrl C Delete Del Download gt Rearrange Object Properties Alt Return Figure 5 NetPro Open Object TAMK University of Applied Sciences PROFIBUS network config page 95 102 Departement of electrical en
54. evice with SFC 15 DPWR_DAT This function is used to write data into the DP device The step configuration of this function it is the same than the SFC 14 First the function SFC 15 has to be called Figure 71 CALL DEWR DAT Srcli Write Consistent Data to a Standard DP Slave LADDR RECORD RET VAL Figure 71 LAD STL FBD CALL SFC 15 function TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 55 102 Three parameters have to be defined LADDR RET_VAL and RECORD In the Table 6 it is explain the description for each parameter Table 6 SFC 15 function description Parameter Declaration Data Type Memory Area Description LADDR INPUT WORD Ag MDL Configured start address from the process constant image output area of the module to which the data will be written Note Addresses have to be entered in hexadecimal format For example diagnostic address 100 means LADDR W 16 64 Source area for the user data to be written This must be exactly as long as you configured for the selected module with STEP 7 Only the BYTE data type is permitted If an error occurs while the function is active the return value contains an error code RECORD INPUT ANY l Q M D L RET_VAL OUTPUT INT I Q M D L The start address LADDR to write data into the frequency converter is at the address 256 100 in hexadecimal format Therefore this value will be ent
55. ew Options Window Help Dae ee me amp ao go fA 82 rx 0 UR Find 1 J PS 307 54 z I cru 315 2 DPO __PROFIBUS 1 DP master system 1 _ Profile Standard PROFIBUS DP fa Dls2 DC24 J DO32xDC24 0 54 a OO ja Figure 8 HW Config Drag and drop Vacon NX device 4 Additional Field Devices 3 Drives B Yacon CX2020PT Switching Devices BS EI Gateway 5 Compatible PROFIBUS CiR Object Closed Loop Controller Configured Stations DP VO slaves DP AS i DP PA Link ENCODER ET 200B TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network config page 97 102 The Properties PROFIBUS Node interface Vacon NX dialog box automatically opens Figure 9 Here set the PROFIBUS address for this DP slave to 3 and click Ok to return the HW Config station screen Properties PROFIBUS interface Vacon NX enera General Parameters Address v Order number GSD file type file YAC29500 GSD Family Drives DP slave type Vacon Nx Transmission rate 1 5 Mbps Designation Vacon N3 Subnet Addresses Node Master System Diagnostic address 1022 PROFIBUS 3 Properties DP master system 1 SYNC FREEZE Capabilities iV Watchdog Cancel Help Figure 9 Properties PROFIBUS Figure 10 Properties DP slave interface Vacon NX Now double click on the Vacon NX box This open the DP Slave Properties dialog box Figure 10 I
56. f Applied Sciences Departement of electrical engineering Bibliography page 71 102 Others 15 Overview to Alimentation des machines asynchrones pdf file referred to 10 06 2010 Available http www techniques ingenieur fr book d3620 16 Overview to Automates programmable industriels pdf file referred to 10 06 2010 Available http www techniques ingenieur fr book s8015 TAMK University of Applied Sciences Departement of electrical engineering Appendices page 72 102 14 Appendices Appendix 1 Designation Vacon NXP frequency converter Appendix 2 PROFIBUS GSD file Appendix 3 User manual Coiler drive project creation with STEP 7 Appendix 4 User manual Coiler drive HMI configuration with WinCC Appendix 5 Programming and configuring the PROFIBUS DP network Appendix 6 Specifications for function SFC 14 and SFC 15 TAMK University of Applied Sciences Departement of electrical engineering Designation Vacon NPX page 73 102 Appendix 1 Designation Vacon NXP frequency converter NXP 00 5 AOSHI 345 ALAZASD2CS Option boards each slot is represented by two characters where Ax basic 1 0 board Bx expander I O board Cx fieldbus board Dx special board Control F standard FR9 and NXC N standard IP00 FR10 and NXC with IP54 control unit enclosure G as F but varnished boards Q as N but varnished boards Cooling S standard air cooled Supply p pulse T 12 puls
57. g Install GSD File 2 The direct link is http www vacon com Default aspx id 463715 visited 05 05 2010 TAMK University of Applied Sciences PROFIBUS network config page 96 102 Departement of electrical engineering Click on the Browse button and check if the GSD file can be open from the GSD folder or from the NSMET folder In this example it is open from the NSMET folder Select the vaco29500 gsd file and click on Install button Figure 7 Install GSD Files x Install GSD Files from the directory ka CAProgram Files Siemens Step 45 OAT ASN SME T Browse SIP_OOSC gte English SIP_OOSC gst French SIP_OOSC gg German SIF_OOSC gsi Italian SIP_OOSE gzs Spanish sly 180b4 ged Default slvE0b4 ged Default vaceJ500 ged Default vaco ged Default sadza 200 Default 1580204 200 Default 2580204 200 Default z ACAN A TU bs Ms Install Show Log Select All Deselect All Figure 7 HW Config vac29500 GSD file installation rm it I Help Now the GSD file is installed in the Siemens database and the frequency converter NXP can be selected For this click on the upper right hand side of the screen and select the PROFIBUS DP folder gt Additional Field Devices gt Drives and drag and drop the Vacon NX device Figure 8 A HW Config SIMATIC 300 Station Configuration Coiler_Drive mig Station Edit Insert PLC Yi
58. g nierie Campus Meinau http www ipst u strasbe fr pat autom siemens step7 htm VACON 2010 Vacon a leading supplier of variable speed AC drives Retrieved June 01 2010 from VACON driven by drives http www vacon com TAMK University of Applied Sciences Departement of electrical engineering Bibliography page 69 102 E documents Manual Siemens 1 Overview to Configuring Hardware and Communication Connections STEP 7 V5 1 pdf file referred to 4 06 2010 Available documentation package order number 6ES7 810 4CA05 8BAO 2 Overview to SIMATIC Working with STEP 7 V5 1 pdf file referred to 4 06 2010 Available documentation package order number 6ES7 810 4CA05 8BA0 3 Overview to System Software for S7 300 400 System and Standard Functions pdf file referred to 4 06 2010 Available documentation package order number 6ES7810 4CA05 8BRO 4 Overview to SIMATIC Programming with STEP 7 V5 1 pdf file referred to 4 06 2010 Available documentation package order number 6ES7810 4CA05 8BRO 5 Overview to SIMATIC WinCC V7 0 Getting started pdf file referred to 4 06 2010 Available documentation package order number A5E02211557 01 6 Overview to SIMATIC HMI WinCC flexible 2007 Compact Standard Advanced pdf file referred to 4 06 2010 Available documentation package order number 6AV6691 1AB01 2AB0 7 Overview to SIMATIC HMI WinCC flexible Getting Started First Time User pdf file referr
59. gineering 6 Final thesis Prosramma ble Togic COMO NCR oiaren a a E tient eausagretiagtes 15 OL INTOdUCU O imos E E rer een mee rer omens reer eee 15 02 Demo aTi cosas ware tele s dear ae Somiguees A T 16 Do lt ERO CESS OM Fades scenes ca satires dea oe ac en tated eae eee esau ede eee ea deere 19 bA iinpur Output module O erens e a 19 O3 Ori ESCIEN Se a A E EEE E 19 OO AUXI a E A 20 O Jroa NC aa N A waa eslesiated ooemeisnacdnuadseasthns tacks 20 OS Lant ud Con ara ET E 21 oS Instn Aist L cepere T 21 G02 Oruca Rex CS TE enaa a E E 21 66 5 Ladder Diagram LAD ccc tic ecco 22 694 Function Bloe Diagrini POD scccssgsscatesvzesenasecest tea ee 22 69 PECIMMEcoler dive ssoriueioriirer iie E Tree E 23 SeNSOrS r NE CONE IVE PeereRnarmreterrTa nEEe Sere eT ree ENN Cena Eryn ERLE TSese etre 24 Fads Tenson SCNSOL cascan o E E NEN 24 J2 OPEC SENSO minekin ae a a er Sete See nate 25 Software for the frequency converter ic fouasactvaziovereass jcsssatiasdaaraecacdeashacnseatadessusdeandeunsdas 26 Sk 0 Gi LOdE AE A ere eer eres 26 8 2 INCI a steno ni a en ahaha a des tesa hansen sa Seaseteibecieme idea tenetacedentedeuteassaeaaecetat 27 TAMK University of Applied Sciences Departement of electrical engineering Final thesis Dr SOO PE Vab etl tive at ats s aarecatinted eat E qoboapacuantssasesncauestausets 28 A ME lc ce Steamers semen este S A see AAN Enea omens E eter ea teen Oem ene ee 28 Olt Presentation Ot ol EP si sasicc
60. gineering Vacon frequency converters are not in the Siemens data base If we want to be able to use it like a slave we need to install a GSD file in the Siemens data base GSD file can be found on the website manufacturer more details in chapter 11 3 1 Open your internet browser and go to www vacon com click on Support amp Downloads and after that on Software Finally click on Field bus conf files and download the Vacon NX Profibus GSD vac29500 gsd The GSD file can be found in the appendix 1 When the file is downloaded cut it and paste it in these two folders e C Program Files Siemens Step7 S7DATA GSD e C Program Files Siemens Step7 S7DATA NSMET The right way is to paste only in the first folder but if the version 5 4 is used it doesn t work To be sure it s better to paste the gsd file in the both folder To install it in STEP 7 in HW Config click on the Option menu and Install GSD File Figure 6 Ei HW Config SIMATIC 300 Station Configuration Coiler_Drive DiJ Station Edit Insert PLC view eemeue Window Help Customize Ctrl Alt E 1 fa PS 307 54 2 CPU 315 2 DP 1 x2 a oP Ja DI32xDC24 d DO32xDC24 0 54 Configure Network Symbol Table Ctrl Alt T 3 a PROFIBUS 1 DP master system 1 Edt Catalog Profile ES 0 Update Catalog 0 Oo mo eo Cd Install HW Updates Install GSD File Find in Service amp Support Figure 6 HW Confi
61. gure 3 The layon roller also referred to as a pack roller or a ride roller serves several possible needs depending on the application Good amp Roisum 2008 i O Figure 3 Center winder with layon roller Good amp Roisum 2008 6 First it reduces air entrainment into the winding roll Second a layon roller serves an important role in the control of winding wrinkles and finally a roller of some sort may be required to support the weight of the winding roll to reduce deflection in the system Good amp Roisum 2008 Web industries page 4 102 TAMK University of Applied Sciences Departement of electrical engineering Web industries page 5 102 In many winders a drive motor is connected to the layon roller rather than winding roll These winders are called surface winder as seen in Figure 4 Good amp Roisum 2008 a Na O Figure 4 Surface winder Good amp Roisum 2008 6 Surface winders are the norm in paper mills but are founded in many other industries The only one limitation with surface winders is that at low nip loading the winder can unhook when the friction forces between the drums and the outer layer are insufficient to wind a roll Good amp Roisum 2008 The last common class of winder is the center surface winder as shown in Figure 5 de OF Figure 5 Center surface winder Good amp Roisum 2008 6 Two independently controlled motors are in the windup section In one arrangement one
62. hat is present in the frequency converter Profibus NXOPTC3 option board Bus connector Jumpers Interface board connector Figure 4 7 Vacon Profibus option board MAOGPICS Shield 1 Cableshield Supply voltage p Receive Transmit data plus B RxD TxD N 4 _ Receive Transmit data minus A DGND Lo Data ground reference potential for VP Figure 76 PROFIBUS NXOPT C3 option board e document 16 Vacon Profibus field bus Board OPT C3 is connected to the field bus through a 5 pin pluggable bus connector Figure 77 OPT C3 terminal e document 16 As seen in the Figure 77 the Receive Transmit data minus A has to be plugged in the slot 4 and the Receive Transmit data plus B in the slot number 3 TAMK University of Applied Sciences PROFIBUS network page 58 102 Departement of electrical engineering But the grounding has to be prepared first There are three manners of grounding but the most effective and recommended is grounding by clamping the cable to the converter frame Strip about 5 cm of the PROFIBUS cable as shown in Figure 78 Figure 78 PROFIBUS cable stripped Figure 79 360 connection When it is done insert the red and green data cables into terminal 3 for the red and terminal 4 for the green Use a 360 connection to ground the cable shield as shown in the Figure 79 after this step the cables configuration is done Now let s see the configuration of the f
63. he second writing function create a new network and in the same way create the second writing function for the process data and the data block 32 as shown on Figure 74 and 75 RA LAD STL FBD_ DB32 Coiler Drive profibus SIMATIC 300 Station CPU 315 2 DP 1 G File Edit Insert PLC Debug View Options Window Help Daei H amp fm ao Sa ae se eee Initial value Coment ae 9 Libraries Figure 74 LAD STL FBD DB32 configuration CALL DPWR DAT oes Write Consistent Data to a Standard BP Slave LADDR W 16 i0s RECORD DES2 process write P DB32 DB20 0 Temporary placeholder variable RET VAL MWzZ06 NOP 0 Figure 75 SFC 15 process data function configured After all these steps the reading and writing function is configured Save the project and upload it into the PLC as seen in the chapter 10 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 57 102 11 5 Cable and connector configuration To have a connection between the PLC and the frequency converter one PROFIBUS cable as on the Figure 60 has to be used The cable links the CPU DP port in the PLC and the PROFIBUS card port in the frequency converter 11 6 Frequency converter Vacon NXP configuration Two types of PROFIBUS field bus boards exist the OPT C3 and the OPT C5 It will be explained the configuration only for the first field bus boards Figure 76 because it is this one t
64. i s D nd h statior to receive the messa s SA Source Address Source address byte indicates which station is to transmit the message Format with variable information field length i T T T f FC Frame Control Control byte contains details about the service used for this message SD2 LE Ler SD2 DA SA FC Data unit FCS ED and the priority of the message Data Uni Data unit contains the useful information of the telegram and details L 4 to 249 sbout an extended address if applicable ol t ack wiedaqmer j I S 10 a KNO ledg ient FCS Frame Chec Check byte contains a te legram check sum whic s obtained by ANDing SC Sequence all telegram elements without ising a carry Dit ED End Delimiter End byte ind cates the end of the tele gram Token telegram SD4 DA SA Figure 62 PROFIBUS telegram formats Decentralization with PROFIBUS DP 2000 24 The following types of errors can be detected Figure 63 Character format parity overrun Protocol error framing error Start and end delimiter error Frame check byte Telegram length error error Figure 63 Errors who can be detected e document 16 The addresses to 0 from 127 can be used there are therefore 128 addresses usable Normally the address 0 is used by diagnostic tools address 126 is for devices who receive their address by the bus and 127 is the distribution address Addresses from 1 to 125 can be freely employed for masters and slaves e docu
65. ica While most printing companies are small several are large enough to do serious research and development The Table 1 shows that the web industry is very large and diverse In fact web industry may very well be the largest industry Paper and textiles are the first materials produced as a web steel and plastic followed Roisum 1998 Table 1 Web material and product examples Roisum 1998 2 Photographic Tape adhesive Tape magnetic Wrap food Wrap shrink Wrap stretch Filters Insulation Medical garment and covers Personal hygiene products Currency Labels Magazine Newspaper Tissue Towelling Waxed Wrapping Writing TAMK University of Applied Sciences Departement of electrical engineering Web industries page 3 102 2 1 Coil history For 5 000 years thin materials as for example papyrus had been made in web It is an economic advantage to make a product long because it can be manufactured continuously In 1798 Louis Nicolas Robert made for the first time webs continuously with the invention of the Fourdrinier paper machine Roisum 1998 It took until the early of 19th century to see paper makers use coils of paper and not traditional sheets of paper Over the years the coils built became more and more longer and wider Today a coil for a newspaper machine is ten meter wide ten kilometer long and can weight ten tons Roisum 1998 2 2 Coil fabrication The actual fabrication is made by a c
66. ice Device selection Device type E Micro Panels 4 Mobile Panels 4 Basic Panels Panels Multi Panels SIMATIC C Sinumerik Simotion PC Panel PC PC fee ee Ee ee i WinCC flexible Runtime Further devices version of device 1 3 1 0 v Figure 3 WinCC Device selection TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 84 102 Then choose the MPI DP connection and select the right PLC for the coiler drive SIMATIC S7 300 400 Figure 4 Sh WinCC flexible Advanced In this type of project a controller is connected directly to an HMI device Select here the HMI device connection and controller conforming to your plant configuration e Click on the HMI device to select another type of HMI device e ifthe selected HMI device supports more than one resolution select your setting from the list e Select your controller type fror the list Connection Controller Select project type gt Screen template Screen navigation System screens O Libraries Project information C es Util sass saus suss WinCC flexible Runtime BE 1024x768 a MPDP SIMATIC S7 300 400 Figure 4 WinCC HMI device and controller Next step is to choose what kind of template will be used for the interface If something really basics is needed it s good to use this wizard but in our case the i
67. igure 1 SIMATIC New Project Set the Storage location path enter a name for the new project confirm and quit with the OK button Now you are in the main menu of SIMATIC Manager The object folder MPI has automatically generated which you can see in the right hand half of the project screen It is each time automatically generated because MPI is the standard programming and communication interface of the CPU Now new objects have to be inserted In the left hand side of the project screen select the project open the shortcut menu with the right mouse button and select the command Insert new object TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 76 102 Insert SIMATIC 300 station as seen on the Figure 2 the newly inserted objects appears in the right hand half of the project screen SIMATIC 400 Station PLC SIMATIC 300 Station SIMATIC H Station SIMATIC PC Station SIMATIC HMI Station Other Station SIMATIC 55 PG PC Rename F2 Object Properties Alt Return MPI PROFIBUS Industrial Ethernet PTP 57 Program M Program Figure 2 SIMATIC Manager Insert Station As seen in the chapter 9 1 two ways are possible in our case we choose to configure the hardware first Hardware configuration Next step is the configuration of the hardware used on the S7 300 programmable controller Call the HW Config ns HW Config module either
68. ion is active the return value contains an error code RECORD OUTPUT ANY Destination area for the user data that were read This must be exactly as long as you configured for the selected module with STEP 7 Only the data type BYTE is permitted System Software for S7 300 400 System and Standard Functions A5E00069892 02 15 17 TAMK University of Applied Sciences Departement of electrical engineering SFC 14 and SFC 15 functions page 100 102 SFCs for Distributed I Os Error Information W 16 woo fro se permed e You have not annie a module for the specified logical base address or e you have ignored the restriction concerning the length of consistent data or e you have not entered the start address in the LADDR parameter in hexadecimal format A type other than BYTE is specified in the ANY reference 8093 No DP module from which you can read consistent data exists at the logical address specified in LADDR 80A0 Access error detected while the I O devices were being accessed Slave failure on external DP interface module The length of the specified destination area is not identical to the user data length configured with STEP 7 System error with external DP interface module System error with external DP interface module a The data haven t yet been read by the module 80C2 System error with external DP interface module Z o Z 80Fx_ System error with external DP interface module Z o Z 87xy
69. ith priority as such E A gt B AND C gt D It allows to evaluate the right part and to assign the value in E This language is used when there are a lot of complex algorithms with numerical treatment For Boolean function it is never used e document 4 5 TAMK University of Applied Sciences Departement of electrical engineering PLC page 22 102 6 8 3 Ladder Diagram LAD This language uses a graphic shape with contacts The application is introduces by one or more network s and a network is formed by graphical elements or function blocs connected between them by lines Figure 27 Lines start on the left alimentation and ended on the right Output 1005 1012 Q008 NU e ee Figure 27 Example of LAD e document 4 5 This language is very efficient for combinatorial systems and it is used a lot in industries But LAD is difficult to program with time functions or for independent outputs e document 4 5 6 8 4 Function Bloc Diagram FBD FBD is a language very close than LAD language In this language contacts are replaced by boxes Figure 28 Inputs are on the left and outputs on the right Figure 28 Example of FBD e document 4 5 Blocs are founded in a library or are created by the users A very interesting thing is that with the use of blocs mistakes are decreased Restrictions are the same than LAD efficient for combinatorial systems but difficult to program with time functions or
70. ive e Set references e Operate the NXP data logger and more FOB_O 84 _pen vcn Advanced C OFFUNE OH 49 meam il Spears Monitoring window window parece Diagnostic window window Pt Wating Tagget fey Aun faa G m D Figure 34 FC Drive main window The Vacon NC Drive also allows to monitor up to eight user specified variables simultaneously on a graphical trend screen In the Vacon NXP it can also operate the data logger and communicate via a CAN network with up to 254 drives VACON 2010 TAMK University of Applied Sciences Departement of electrical engineering Software page 28 102 9 Software for the PLC Two different software are also used to manage correctly the PLC The first one is STEP 7 for the PLC program and the second one is WinCC for the human machine interface Both are made by Siemens and they are in the SIMATIC suite 9 1 STEP 7 This chapter explains the notions about the STEP 7 software in a general case All the steps to create a STEP 7 project for the coiler drive creation of a new project hardware configuration programming and downloading to the PLC are explained in the User manual Coiler drive project creation with STEP 7 appendix 3 9 1 1 Presentation of STEP 7 This software allows having an access to Siemens PLC in our case the SIMATIC S7 300 The standard STEP 7 packages comprise a number of applications that you can see on the Figure 35 Set PG PC
71. l the work done this structure is used after a brief introduction to explain winder process the presentation of the coiler with its different elements and the software used is introduced Then the main steps to create a program for programmable logical controller with the STEP 7 software and the creation of the HMI with WinCC software are explained The last part contains the procedure to create and to use a PROFIBUS network with the PLC Simatic 57 300 and the Vacon NXP frequency converter TAMK University of Applied Sciences Departement of electrical engineering 2 Web industries Web industries page 2 102 Paper is the oldest of the web industries with more than a century of culture and history A web is a long flexible and thin material the paper industry holds many web records such as manufacturing speed 2 300 m min converting speed 3 050 m min and width 10 m Roisum 1998 The demands of these high speeds and wide widths also necessarily mean that the paper industry tends to have more precise and robust machinery The converting industry drying laminating packing etc is bigger in terms of numbers than any other web manufacturing industries There are 10 000 converters in North America but many of the converting companies and machine suppliers are smaller than paper industry companies Roisum 1998 The largest web industry in terms of numbers is the printing industry about 50 000 in North Amer
72. lied Sciences Departement of electrical engineering Software page 36 102 Displaying alarms Critical process states automatically trigger an alarm when the set point value is exceeded for example Archiving process values and alarms The HMI system can log alarms and process values This feature allows you to log process sequences and to retrieve previous production data Process values and alarms logging The HMI system can output alarms and process value reports This allows you to print out production data at the end of a shift for example Process and machine parameter management The HMI system can store the parameters of processes and machines in recipes For example you can download these parameters in one pass from the HMI device to the PLC to change over the product version for production Now let s see more information about WinCC e document 6 9 2 2 Presentation of WinCC It is a software made by Siemens to create HMI interface between the person and the machine WinCC allows the operation and observance of the process that run in a machine The communication between WinCC and the machine takes place via an automation system Different objects are necessary to be configured to monitor and operate the system such as e Screens to show and operate the processes on the control device e Tags to transfer data between the operating device and the installation e Archive to store the process data e Alarm
73. llistaa helpot asetukset ja lis ksi helpottaa prosessin valvontaa Nykyisin melkein kaikissa prosesseissa onkin k yt ss HMI HMI n avulla kelaink yt st saadaan t ysin konfiguroitava teollisuuskone Jatkossa on tarkasteltava muokkausten poistojen ja lis ysten asetuksia Hakusanat kelaink ytt ihmisen ja koneen rajapinta HMI Profibus ohjelmoitavan logiikan ohjain taajuusmuuttaja Siemens Vacon TAMK University of Applied Sciences Departement of electrical engineering Final thesis pape Foreword This work has been carried out at Tampere University of Applied Science in Finland during the second semester 2010 academic course Working on this subject was a big challenge for me because I learned notions during my training in the Institut Sup rieur Industriel de Bruxelles but I never really practice it I progressed step by step and of course I had problems but it was very interesting to try each different approaches and to finally figure out a solution Luckily I was not alone to do this work Mr Sc Lauri Hietalahti helped me a lot and that is why I would like to offer my most profound thanks to him for his help and for the opportunity to work on this project Also a very special gratitude to Mrs Kirsti Kallio for her help with the translation of my abstract to Finnish to Mrs Ruth Crivelli and Mrs Isabelle Cartier to take the time to correct my text and finally to my teacher Mr Sc Olivier Debia
74. ment 16 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 48 102 11 2 4 Bus Access Control PROFIBUS use a hybrid bus access control mechanism It consists of a decentralized token passing procedure for communication between the active nodes master and the centralized master slave procedure for communication between the active and the passive nodes When an active node bus station has the token it takes over the master function on the bus to communicate with both passive and active nodes The exchange of messages on the bus is organized by means of node addressing Each PROFIBUS node is given an address which must be unique throughout the entire bus system Decentralization with PROFIBUS DP 2000 However in the coiler drive PROFIBUS network there is only one master and only one slave therefore there is not really this kind of notion There is still a token even in DP mono master structure as seen in the figure 64 E AN Slaves passive stations Figure 64 DP mono master structure Decentralization with PROFIBUS DP 2000 34 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 49 102 11 3 PROFIBUS DP in SIMATIC 57 system PROFIBUS is an integral part of SIMATIC S7 systems The I O peripherals are totally integrated in the system by the STEP 7 configuration tool SIMATIC S7 provides integrated or plug in PROFIBUS
75. n the Figure 30 the tension sensor in the coiler drive is shown Figure 30 Tension sensor in the coiler drive TAMK University of Applied Sciences Departement of electrical engineering Sensors page 25 102 7 2 Speed sensor A speed sensor is necessary to measure and to control the speed of the nylon web A system of infrared measuring has been chosen The design of a plate with holes has been fixed to the auxiliary cylindrical coil This method is cheap and it is also used in industry Three parts compose this sensor The first one is the infrared light encoder OMROM E3JK DS30M1 it is put in the front of the speed rotating plate and sends a signal to the plate which is reflected and it returns to the infrared light sensor The second one is the speed rotating plate fixed to the auxiliary coil It was designed in order to achieve fifty pulses per revolution The last part is the frequency to voltage converter AXIS 10 ATP2 3 that obtains a frequency signal from the infrared light encoder The frequency converter needs a voltage signal so it is required to change the signal by means of the converter Therefore the converter transforms the frequency signal in a voltage signal for the frequency converter Zarza amp Garcia 2005 On the Figure 31 the speed sensor in the coiler drive is shown Figure 31 Speed sensor in the coiler drive TAMK University of Applied Sciences Departement of electrical engineering Software
76. nput but we don t use the letter O for output it s too close than 0 zero so the letter Q is used Q 4 3 for example for an output address e document 5 9 1 3 The program The program will be placed in the PLC its name is OB for Organisation Block The main program will be in the OB1 and in this block we can call other functions like FB or FT for example To program in the OB we need to choose between three main languages LAD FBD or STL By default there is no IL language in STEP 7 e document 4 LAD language As seen in the chapter 7 8 3 the LAD language is a series of networks that will be covered sequentially The inputs are represented by switches or inverted input release by coils or flip flops There are also unary operations I O inverter pending a face amount or down The outputs are mandatory right of the network must be clearly defined our I O either directly by their code or with their name defined in the symbol table enter name in quotation marks It connects the elements in series to the AND function and in parallel to the OR as seen in the Figure 40 Ladder Logic LAD Suitable for users from the electrical engineering industry for example Green Lig Key 1 rr Key FF he m m Figure 40 STEP 7 LAD language e document 4 We may use internal bits can be used in coils and switches as used in a calculator memory for example to store an intermediate result We can also introduce mor
77. ns used are basic English Mnemonics Description A And O Or Assign Here the code Figure 8 it allows when the Start button is pushed and that the Stop button is not pushed to start the process alimentation in the coiler drive And of course to stop the alimentation when the Stop button is pushed Al O Start Tz 0 start process O Alim process 04 1 process alimentation l A Scop T2 2 stop process Alim process Otad process alimentation Figure 8 LAD STL FBD Main program The Start button for example has the address I 2 0 This variable or symbol is configured in the Symbols table in that table every symbol receive an address a data type as seen on the Figure 9 Therefore the first step is to fill this symbol table with all variables and to give for every variable one address cautiously TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 80 102 7 ead mba Coiler Drive profibusiS MATIC 300 Station CPU 315 2 DP 1 ace T Ona acct pac srt 2 Breki Q 45 BOOL break mort o 3 Break Q 4 amp 6 BOOL break motor a Cycle Execution OB 1 0B t o O 5 DPRDDAT SFC 14 SFC _14 Read Consistent Data of a Standard DP Slave 6 DPWR_DAT SFC 15 SFC _15 Write Consistent Data to a Standard DP Slave a Start 20 BOOL process Co i wee a har oo o e e I IIIo a vaT read AT 2 a2 A vaT write MAT a E a
78. nterface will be done by our self so it s better not to use it Therefore unmark all the fields to have an empty screen like on Figure 5 G WinCC flexible Advanced Create a custom template for your screens You can use this template in the project for each new screen created for the HMI device e Specify if you wish to create a header navigation control and alarm line or alarm window e Select the elements to be included in the header You can specify a graphic file for the company logo e Selectthe position and style of the navigation bar and alarm line alarm window e If several different HMI devices are selected their combined capabilities are displayed Select project ype 3 HMI device and controller 7 Screen title Il Date and time Company logo Screen navigation BB Navigation contro Position C let below C right Buttons System screens Libraries Project information one row two rows with text C with graphics BB Alarm line alarm window Alarmline above Alarmlinebelow Alarm window Figure 5 WinCC Screen template TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 85 102 Click on Next to apply the standard settings provided on the page Screen navigation same for the pages System screens and Libraries Then the last step in this wizard is to enter information on the
79. number 1 Figure 5 SIMATIC 300 1 Configuration Coiler Drive Tek Station Edt Insert PLC Wew Options Window Help Diu g ae ba HO BW rw Eind mtini Profile Standard 2 3 E SIMATIC 400 amp SIMATIC HMI Station fl SIMATIC PC Based Control 300 400 9 o uF SIMATIC PC Station 6E57 307 1EADDGAAD z Load supply voltage 120 7 230 VAC 24 VOC 5A aad Press Fi to get Help Figure 5 HW Config PS Next open the CPU 300 folder open the CPU 315 2DP folder then select the 6ES7 315 2AF03 0AB0 V1 0 and drag it to the section number 2 The parameter tab of the properties PROFIBUS Node DP Master dialog box Figure 6 opens automatically TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 78 102 Properties PROFIBUS interface DP RO S2 1 General Parameters Address a y If a subnet is selected the next available address is suggested Subnet Cancel Help Figure 6 Properties PROFIBUS interface DP Here you can set the parameters of the DP master interface integrated on the CPU PROFIBUS network configuration will be done in the chapter 14 for the moment click only on the OK button to quit the dialog box Last step is to select the right I O modules Open the SM 300 folder then open the DI 300 folder and drag and drop the SM 321 DI 32xDC 24V in the section 4 The same for
80. oect Texts amp fip Dichonanes amp M Stuctses E Big Veson Management Figure 7 WinCC Start screen TAMK University of Applied Sciences WinCC Projects page 86 102 Departement of electrical engineering Screens some pre configured screen the start screen the template and all the future screens are stored in the Screens area Communication the connection settings between the HMI PC for our case and the controller have been already defined Figure 8 Normally default settings are right and it is not needed to change it Co stertscreen 5Ctonnections S a a a Te e JININ CO I LOINS Connection_1 SIMATIC 57 300 400 jon M Parameters fea pointer WinCC Flexible Runtime Station Interface MPI DP v S CEI HMI device Network PLC device Type Baud rate A TTY Profile MPI v Address l2 187500 v R5232 Highest station address HSA Expansion slot lo R5422 Address 1 J 31 N R5485 Access point 57ONLINE Rack 0 Simatic M Only master on the bus Number of masters 1 M Cyclic operation Figure 8 WinCC Connections The last step is to go in the Tag screen In this screen Figure 9 all the symbols used by the HMI have to be defined It s better to use the same name that for those that are in the symbol table in STEP 7 Here examples of Tags in the coiler drive At the end it is important that addresses are the same addresses that in the PL
81. ol the frequency It may use thyristors IGCTs or IGBTs Amin 2001 5 1 4 Control and regulation circuit The electronic control unit manages circuit transmit signals to the rectifier the intermediate circuit and the inverter It carries out control and subjugation of the machine through the static inverter so that the user can directly control the speed Its design depends primarily on the control strategy chosen Vector control or Scalar control Amin 2001 TAMK University of Applied Sciences Departement of electrical engineering Frequency converter page 13 102 5 2 Frequency converter drives As seen in the squirrel cage motor s chapter the electric motor speed is related to the frequency of the stator s currents This link allows a mathematical control of the rotor s speed by controlling the frequency of the stator s current Thus there is a direct relationship between the driving frequency current to the stator and the rotor mechanical s speed which allows for any desired mechanical s speed to set the corresponding stator frequency This is the frequency converter s principle controlling a mechanical speed by controlling the frequency of the stator current There are many advantages to use a frequency converter such as shown in the Figure 16 e Easy speed variation e Generators of harmonic current on the network e Heavy load inertia starting e Hig starting torque e Low starting c
82. ontinuous way The paper is winded without stop and when the coil has its maximal size it is evacuated and a new coil support is loaded The operation has to be made without deceleration of the machine and mostly without breakage paper Roisum 1998 As seen in Figure 1 the solution is showed to wind a coil continuously Two or more center winds are placed on a rotating axis that allows the other winder to be ready to start a new roll on the fly Roisum 1998 Centerwind 1 Mf Nii j WN n O Z 5 wT Figure 1 Turret winder Galindo 2004 50 Centerwind 2 Such coils require a very careful handling Indeed a coil doesn t behave like a solid for example if a coil is placed on the ground the lower part is going to have a lot of stress and will grovel This can cause some deformations can make unusable because there will be dolt problem and this created suddenly and breakage Roisum 1998 TAMK University of Applied Sciences Departement of electrical engineering 2 3 _Winder machine There are four kinds of class of winder The simplest class is a center wind as seen in Figure 2 where the wound roll is driven through its core The drive is usually an electric motor who establishes incoming web tension between the wound roll and upstream driven element Good amp Roisum 2008 OY Figure 2 Center winder Good amp Roisum 2008 6 More complex is a center winder with layon roller as seen in Fi
83. ossible addresses in the Hardware Configuration Editor HW Config TAMK University of Applied Sciences Departement of electrical engineering Software page 31 102 If you choose the second option you have to determine each address yourself depending on your selected components and you cannot call these addresses via STEP 7 e document 3 4 9 1 2 Hardware configuration Let s take the first option and add a station here S7 300 to our project After that we need to define the entire hardware configuration Figure 38 Rack Type of processor Type of power I O module supply Figure 38 Hardware configuration e document 5 The last step in the hardware s configuration is to define all the symbols in the symbols table It s a very important part because symbols will be employed for programming and they are directly connected to an address in the I O module As seen in Figure 39 the I O module has different addresses Digital output module Byte 4 Bits Oto 7 module Byte 0 Bits 0 to T Li g Digital output module Byte 5 Bits Oto 7 Digital input module Byte 1 Bits 0 to 7 Figure 39 Addresses in the PLC e document 5 The bytes 0 and 1 are used for the input addresses and the bytes 4 and 5 for the output addresses TAMK University of Applied Sciences Software page 32 102 Departement of electrical engineering The letter I is used for Input addresses I like I
84. project and to click on the Finish button Figure 6 Sh WinCC flexible Advanced Project Edit Yiew Insert format Faceplates Options Window Help Dw Mo w X Xe 1O AA Enter information about the project to help you to later identity it in WinCC flexible Enter comments here e Press Finish to generate the project with your settings eee HMI device and controller C7 Coiler Drive HMI HMI for the Coiler Drive Screen template Project author seine ase Screen navigation 7 ze Crivelli Manuel 17 05 2010 System screens Creation date Libraries 7 SAL 571772010 Figure 6 WinCC Project information The project wizard has already created some elements as shown on Figure 7 WinCC flexible Advanced Pro i Project gdt yew vn ome tener Options Window teb i i i re A LELT Lk TEAL ee LE aaam s EU jOa gad siae w A nl CEES ERE EEE AE ANCES HTE J lss JO E _ ___ Project Ester soem om 7 lee Coder Drive HMI l ik 2 ee i Simple Objects 4B Add Screen i O Terpise Une O Stat Screen A Polytine E Polygon a Tag Ellipse TE one 5 ij Alam Management E Rectangle Analog lams A TextField E Discrete Alama BE 10 Peld D Settings Gy Oate Time Field w iy Historical Data IB Graphic 10 Field w Symbolic 10 Field E Graphics View Ter and Graphics Lists me bute Rurtive Use Adrraresti aton ie FES Device Setings BF switch m E Language Settings p sx Project Languages amp Grapho g Pr
85. r Drive C Documents and Settings labra Coiler_D EP File Edit Insert PLC view Options Window Help Ce SP ae amp Jal 2 a Pol EE ie Ba lt Noriter gt S ES a PROFIEL Sij Coller Drive Open Object Ctrl Alr o Cut Chrl Copy Chrl c Delete Del Print Rename Fe Object Properties Alt Return Figure 2 SIMATIC Manager Open Object Select the PROFIBUS subnet in violet PROFIBUS 1 and right click to open the shortcut menu Select the command Object Properties Figure 3 NetPro Coiler_Drive Network C Program Files s proj Coiler 1 aa Network Edit Insert PLO view Options Window Help co i S Be 5 win P m Za r MPIC 1 MFI PROFIBLIS 1 PROFIBLIS Copy Ctrl Delete Del Frink parameters Rearrange Object Properties 4lt Return Figure 3 NetPro Object Properties In the dialog box Properties PROFIBUS open the Network Settings Here you can set all relevant network parameters for the PROFIBUS subnet Figure 4 Properties PROFIBUS General Network Settings Highest PROFIBUS Options Address Change Transmission Rate 45 45 31 25 Kbps Profile Standard Universal DP FMS User Defined Bus Parameters Cancel Help Figure 4 NetPro Properties PROFIBUS TAMK University of Applied Sciences PROFIBUS network config page 94 102 Departement of electrical engineering Highest PROFIBUS addr
86. remained with the four bytes of process data field because it was impossible to start the motor for example It means that the Parameter field works properly but the Process data field does not work One reason can be the error code 8093 in the RET_VAL for the two functions in the process data field TAMK University of Applied Sciences Departement of electrical engineering Final conclusion page 67 102 12 4 What is next There is still much work to do before that the coiler drive process is operational First of all the PROFIBUS network has to be fixed and tested The process data field problem has to be figured out with the help of Vacon When the PROFIBUS network is operational other tasks can be done The main task will be to integrate the interface with STEP 7 the different symbol addresses in WinCC are already made but not in STEP 7 because the PROFIBUS network is needed to test every symbol address When the integration will be done every button and parameter has to be tested under real conditions Some parameters should be analysed for modification deletion or addition Another task will be to do a safety program with STEP 7 Its task will be to check every parameter set by the user in the control panel If the user sets the rotating speed value too in the control panel for example the program has to send an error message and block the start of the process If the process works properly it is possible to imagine a f
87. requency converter interface First in the Expander Board Menu find the NXOPTC3 Parameters and in the Slave address settings G7 5 1 1 put the number 3 as shown in the Figure 80 a g Se Expander Board Gi3G5 ea a A i aba Slave address 126 lt o CONFIRM CHANGE CHANGE VALUE Figure 80 Frequency converter settings e document 16 After this step the network should be work To check it two ways are possible The first way is to control the three LED on the PROFIBUS field board The first one shows the PROFIBUS status red the second one the PROFIBUS board status yellow and the last one the Field bus module green more details in the Table 7 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 59 102 Table 7 PROFIBUS status LED e document 16 Profibus status LED PS RED Profibus communicates normally Data exchange between Master and Slave Profibus communication is broken or not started e Bus cable broken or incorrectly connected e Wrong configuration or parametrization data of Master e Master is off line or shut down Profibus board status LED BS YELLOW Option board not activated ON Option board in initialisation state waiting for activation command from the frequency converter Blinking fast Option board is activated and in RUN state lonce sec e Option board is ready for external communication Blinking Option board i
88. ring Insert images WinCC Projects page 88 102 In this chapter the way to insert the TAMK logo will be described It is the same principle to insert pictures in the template or in an another screen Click on the Graphics tab Figure 11 Right click on the New link select New folder link Figure 12 Graphics WinCC flexible Image Folders E My Image Folders gular Cres k amp Simple Objects Line a Polyline a Polygon Ellipse O Circle C Rectangle A TextField ab 10 Field Date Time Field 45 Graphic IO Field Symbolic IO Field lad Graphics View DR Button BT Switch H Bar Enhanced Objects My Controls Graphics Library Figure 11 WinCC Tool gt Graphics tab Mew Folder link Edit Folder link Remove Folder link Rename Folder link Refresh Folder link Figure 12 WinCC Graphics gt New link TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 89 102 Enter the folder s path in the dialog box Figure 13 WinCC flexible ES Add new folder link Name Coiler drive pictures Path G Coiller Drive Reports Picts Figure 13 WinCC Add new folder link Close the dialog bow with the OK button A new link is created and you can find in it all our pictures Drag and drop the TAMK logo in the work area Figure 14 To set properties double click on the
89. rk page 52 102 Three parameters have to be defined LADDR RET_VAL and RECORD In the Table 5 it is explain the description for each parameter Table 5 SFC 14 function description Parameter Declaration Data Type Memory Area Description LADDR INPUT WORD lI Q M D L Configured start address from the area constant of the module from which the data will be read Note Addresses have to be entered in exadecimal format For example diagnostic address 100 means LADDR W 16 64 RET VAL OUTPUT INT 1 Q M D L If an error occurs while the function is active the return value contains an error a a RECORD OUTPUT ANY 1 Q M D L Destination area for the user data that were read This must be exactly as long as you configured for the selected module with STEP 7 Only the data type BYTE is permitted The start address LADDR is a word in hexadecimal format to say which is the byte where data have to be read In the GSD file of our Vacon frequency converter it is written that the first byte is in the address 256 100 in hexadecimal format Therefore this value will be entering in the LADDR parameter LADDR W 16 100 Second parameter is RET_VAL it is used like a diagnostic parameter If an error occurs the error code will be return to the address specified It is important to choose an address not used In our case the address 200 in the memory will be chosen MW means Memory Word RE
90. rsity of Applied Sciences Departement of electrical engineering PLC page 16 102 Since many of applications require analogue processing Figure 19 as such Servo Pneumatic Speed Settings Positioning System Force Measurement Figure 19 Applications with analogue processing The program is stored in an electronic memory and now the tasks of a PLC have rapidly multiplied For example mathematical computing operations timer and counter functions memory setting etc e document 16 The PLCs currently on offer in the market place have been adapted to customer requirements It s really possible to buy a perfect adapted PLC for any applications Miniature PLCs are now available with a little number of I O also available larger PLCs until 256 I O Additional I O analogue positioning and communication modules can be installed to extend possibilities of PLCs e document 16 6 2 Design of a PLC The term programmable logic controller is defined as follows by EN 61131 1 norm A digitally operating electronic system designed for use in an industrial environment which uses a programmable memory for the internal storage of user oriented instructions for implementing specific functions such as logic sequencing timing counting and arithmetic to control through digital or analogue inputs and outputs various types of machines or processes Both the PC and its associated peripherals are designed so that they can be
91. s Max config data per slave 244 bytes TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS page 50 102 Max diagnostic data per slave 240 bytes Cross communication support Yes Yes Constant bus cycle time Yes SYNC FREEZE Yes No 11 3 1 Generic Station Description GSD files GSD files are ASCII files for DP slave contain characteristic device properties of these DP components The characteristics are standardized and the syntax is fixed it allows to check PROFIBUS device data Decentralization with PROFIBUS DP 2000 Characteristics are for example e Name of the manufacturer e Software and hardware version e Designation devices e Transmission rates allowed It is used in our case to be able to install the Vacon frequency converter in the PROFIBUS Network The appendix 2 gives more information about the PROFIBUS network and how to install and use the Vacon GSD file TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 51 102 11 4 PROFIBUS network STEP 7 program To be able to read and write data through the PROFIBUS network some special communication functions have to be used In STEP 7 there are many communication functions but only two are the most used The first one allows reading data and the second one is to write data into the slave the specifications for these functions can be found in the appendix 5 11 4 1 Reading dat
92. s Electric motor page 9 102 Departement of electrical engineering Today with the power electronic progress frequency converters are used to change the speed but also to manage a good start typically with an enough torque and without a too high current in the stator Squirrel cage motors are used in the new TGV and in lots of subway around the world Amin 2001 4 3 General specifications 4 3 1 Slip The Slip is a quantity that reflects the difference in speed of an induction machine compared to a hypothetical synchronous machine built with the same stator It other words it s the difference between the speed of the rotor and the speed of the rotating magnetic field in the stator Amin 2001 The slip should stands around 2 for big motors and around 6 7 for small motors Nns N Ns S the slip in Ns in Hz is the frequency of rotation of the rotating fields called the synchronous speed Ny in Hz is the frequency of rotation of the rotor 4 3 2 Speed control As seen above to change the rotor s speed we need to change the frequency of the rotating field in the stator In other words the synchronous speed has to be changed In the synchronous speed s formula there are only two variables f for frequency and p for phase number If the number of phase is changed the frequency of synchronization will be still a sub multiple of the mains frequency With 50 Hz for example sub multiple of 3 000 rpm will
93. s activated and in FAULT state slow e Internal fault of option board lonce 5 secs Fieldbus status LED FS GREEN Fieldbus module is waiting for parameters from the fre quency converter e No external communication Fieldbus module is activated e Parameters received and module activated e Module is waiting for messages from the bus Blinking fast Module is activated and receiving messages from the bus once sec Blinking Module is in FAULT state slow e No messages from Master within the watchdog time once 5 secs e Bus broken cable loose or Master off line The second way is to use the monitor to see the present status of the PROFIBUS Field bus as shown on Figure 81 Profibus status Waiting parameter from Master 4P Profibus status EE a Waiting configuration from Master Communication established Profibus status Message counter Figure 81 Profibus status The last step is to change in the Menu to say that the frequency converter is managed by a field bus and not by the control panel TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network page 60 102 11 7 Reading and writing communication As seen in the chapter 11 4 to read and to write data into the frequency converter special functions and data blocks have to be used There are two different functions and four different data bocks created in our case because we use the PPO1 mode Figure 82 In this mod
94. s to indicate the operating status of the system on the operating device TAMK University of Applied Sciences Software page 37 102 Departement of electrical engineering In order that the operator can perform tasks the HMI device must be configured The configuration steps necessary to do this Figure 47 are explained here You can found also the practical example for the coiler drive in the manual User manual Coiler drive HMI configuration with WinCC Appendix 4 Designing the N N 4 i solution to the b Creating the be Creating HMI task plod Screens v Structure of Transfer A Multilingual Projects Figure 47 Configuration steps in WinCC e document 6 A project is the basis for configuring the user interface all the objects will be created and configured in it By objects it means e Screen e Tags e Alarms 9 2 3 The Screen The main screen Figure 48 contains different parts In the Project View there is the tree structure that contains all the configurable elements Projects are edited in the Work Area All elements are arranged on the borders of the wok area The Property View is used to edit object properties e g the colour of text TAMK University of Applied Sciences Departement of electrical engineering Software page 38 102 The Toolbox contains a selection of objects that you can add to your screens for example pictures images objects or operat
95. t There are a command part and an operative part The command part recovers information about process status and the operative part is made by actuators that act physically on the process The I O module collects all the data and provides a good communication with the UC A lot of PLCs use removable module with specially ways e document 16 6 5 Storage elements To store data and program PLCs use different kind of memories The Random Access Memory RAM is volatile but there is a battery to save all data The Read Only Memory ROM contains the operating system and monitor PROM and EPROM are sometimes used to specific applications or the save programs e document 16 TAMK University of Applied Sciences Departement of electrical engineering PLC page 20 102 6 6 Auxiliary Mainly there is the power supply which aims to provide right continuous tensions 5V 12V taking into account the little network disconnections There is a fan very important for frame with a lot of modules or in case where the ambiance can become warm The rack whose supports the entire PLC An indicator states that show the presence of a tension a program execution etc e document 16 6 7 Programming The program has to provide all the time an operative cycle that has three kinds of tasks as shown in Figure 26 Acquisition Input Read Values Assignements Output Write Data Pocessing S Figure 26
96. t is shown characteristic like order number device family type and description The diagnostic address is used by the CPU to indicate a DP Slave failure with organization block OB86 Finally to know which address is used for the first byte select the Vacon NX box and on the bottom right click on the rack 0 select Insert Object and then click on NX PPO1 Figure 11 TAMK University of Applied Sciences Departement of electrical engineering PROFIBUS network config page 98 102 eT ee i Insert Object 3 Vacon Nx Isochronous Mode A Yaran We Universal module YACON PPO 1 VACON PPO 2 VACON PPO 3 VACON PPO 4 VACON PPO 5 special Go To gt Assign Asset ID Address Slot 3 DPI Order Number Designation Address O Address VACON PPO 1 256263 256263 EN ARE eee OO ae Figure 11 HW Config Insert Object DP slave HW Config can be closed save the changes and control if in NetPro the PROFIBUS network is done as shown in Figure 12 NetPro Coiler_Drive Network C Program Files 4s proj Coiler 1 ri Network Edit Insert PLO View Options Window Help cE h SS i E I k FROFIBUS 1 PROFIBUS SIMATIC 300 Station Figure 12 NetPro PROFIBUS network check Order Number Desigr TAMK University of Applied Sciences Departement of electrical engineering SFC 14 and SFC 15 functions page 99 102 Appendix
97. ternal DP interface module 80C1 The data of the previous write job on the module have not yet been processed by the module System error with external DP interface module 80Fx sd System error with external DP interface module 85xy o System error with external DP interface module System Software for S7 300 400 System and Standard Functions 15 20 A5E00069892 02
98. the section 5 open the DO 300 folder and select the SM 322 DO 32xDC 24V 0 5V The Figure 7 shows the final configuration wm 0 UR Kl PS 307 5A 0 UR Slot F Module wee number Firmware MPI address address Q address Comment l if ee e gt gccru 316 2 DP E T 2 A Seer e ht e CF S TAN a S G ee a 4 ig Dis2xbcaay BES 321 1BLOO OAAG 5 f D032 DC24v 0 54 6ES7322 1BL00 0AA0 J o Jo o o o OAF O a a I SS a TS San UO eS a Figure 7 HW Config Final Configuration TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 79 102 Programming with STEP 7 software In the Chapter 9 3 1 about STEP 7 software we have seen that there are many different languages First of all only one language has to be chosen it is not obligatory but it is really easier for the user because he will not have too many different languages to read In our case we have chosen the STL language because the SFC functions can be called only with the STL code The program in the PLC is really short indeed there are not many of I O Most of the function will be done through the PROFIBUS network speed settings torque settings etc In Step 7 the main program is in the OB1 block This block is subdivided by networks In our case we only need two different networks The first network contains the code to manage the alimentation of the coiler drive through the control panel STL instructio
99. tion E cru 315 2 0P0 ounces Blocks Press F1 to get Help PC Adapter MPT Figure 36 STEP 7 Main window It can program an individual controller in different languages and takes into account the network of PLC which allows access to any network controller for programming and the possibly to automatic send messages between them e document 3 4 The first step in STEP 7 is to create a project In a project there are the full descriptions of your automation It consists of two main parts e The description of the material e The functional description the program TAMK University of Applied Sciences Software page 30 102 Departement of electrical engineering A wizard is there to help you in the project s configuration you can choose to use it or not Sometimes it is better to not use the wizard it configures default poorly on the controller e document 3 4 Then you can choose two different ways configuring the hardware or creating a program as seen on Figure 37 Designing the solution to the automation task Creating the project Configuring Creating a the Hardware program Creating a Configuring program the hardware Transferring the program to the Figure 37 Option 1 and option 2 e document 5 If you are creating programs with a lot of inputs and outputs it is recommended to configure the hardware first The advantage of this is that STEP 7 displays the p
100. tive point only one station can emit at a time e document 16 11 2 1 Physical Layer layer 1 The coiler drive PROFIBUS network is equipped with a RS 485 transmission The wire is a bi axial cable its colour is purple Figure 60 Braid Pre eek ae sr ii f tag ball Conductive sheet Purple jacket Figure 60 PROFIBUS cable structure e document 16 Data are transmit in an 11 bit character frame see Figure 61 in Non Return to Zero NRZ Bit MSB LSB significance l 2 P R R P aaa a etn eg we we wow wn L Information bits Stop bit with 0 or 1 signal with 1 signal Start bit i Even parity bit with 0 signal with 0 or 1 signal LSB Least Significant Bit MSB Most Significant Bit Figure 61 PROFIBUS UART character frame Decentralization with PROFIBUS DP 2000 17 TAMK University of Applied Sciences PROFIBUS page 46 102 Departement of electrical engineering During the transmission a binary 1 corresponds to a positive level on line RxD TXD P Receive Transmit Data P as opposed to RxD TxD N Receive Transmit Data N In specialized literature the two PROFIBUS data line are also referred to as the A line and the B line A line corresponds to the RxD TxD N signal and the B line to the RxD TXD P signal Decentralization with PROFIBUS DP 2000 11 2 2 Bus connection The standard EN 50 170 recommends a 9 pin sub D plug connector details in the Table 3
101. uency converter the different data blocks have to be used The first step is to put the first eight bytes in the data block 11 and then the last four bytes in the data block 32 TAMK University of Applied Sciences PROFIBUS network page 64 102 Departement of electrical engineering If everything works properly when the frame is sent on the PROFIBUS network the motor starts and the maximum frequency can be read into the data block 10 as seen on the Figure 89 Writing data block SFC 15 function an Format Status value Modify value data block SFC 14 Display Format Status value Modify value DB11 DBB OH B 16 10 DB10 DBB OfHEX B 16 10 9 DB11 DBB 1 HEX B 16 66 B 1G GG DB10 DBB 1 HEX B 16 66 pa DB11 DBB 2 HEX B 16 00 B 16 00 DB10 DBB 2 HEX B 16 00 g DB11 DBB 3 HEX B 16 00 B 16 00 DB10 DBB 3 HEX B 16 00 z DB11 DBB 4 HEX B 16 00 B 16 00 DB10 0BB 4 HEX B 16 00 z DB11 DBB 5 HEX B 16 00 B 16 00 DB10 0BB 5 HEX B 16 00 z DB11 DBB 6 HEX B ie 09 B 16 00 DB10 DBB 6 HEX B 16 13 Ra DB11 DBB 7 HEX B 16 C4 B 16 00 DB10 DBB 7 HEX B 16 39 SZ _ eciess __ ossovema sas vate net abe _ 1 DB32 DBBR O HEX B 1i6 04 B 16 04 B 16 00 A 2 DB32 D0BB6 1 HEX B 16 7F B 16 7F DB31 DBB 1 HEX B 16 00 Y 3 DB32 0BB 2 HEX B 16 13 B 16 13 DBS1 DBB 2 HEX B 16 00 DBg2 DBB 3 HEX B 16 55 B 16 89 DB31 DBB 3 HEX B 16 00 5 Figure 89 View in STEP 7 We can see that in the data block 10 in the VALUE are
102. unction on STEP 7 that allows the change of the winding direction A button is already configured in the interface for this purpose Finally it can be interesting when everything works properly to use a HMI device with a tactile screen SIMATIC HMI KTP400 for example instead of a PC and a kind of User Manual for the students could be made TAMK University of Applied Sciences Departement of electrical engineering Bibliography page 68 102 13 Bibliography Books Amin B 2001 Induction motors analysis and torque control Berlin Springer K Good J amp R Roisum D 2008 Winding Machines Mechanics and measurements Lancaster DEStech Publications Inc R Roisum D 1998 The Mechanics of Web Handling Atlanta TAPPI PRESS Weigmann J amp Gerhard K 2000 Decentralization with PROFIBUS DP Erlangen SIEMENS Final Thesis Bravo Zarza J amp Garcia Garcia J L 2005 Design of coiler drive process and their regulation by feedback system Tampere FI Tampere Polytechnic Galindo J M 2004 Frequency converters controlled by PC in coiler drive process Tampere FI Tampere Polytechnic Websites EURODRIVE S 2010 SEW EURODRIVE Gearmotors Frequency Inverters and Decentralized Drive Engineer Retrieved April 23 2010 from SEW EURODRIVE http www sew eurodrive com Trau P 2006 Novembre Utilisation de STEP 7 Retrieved April 15 2010 from UFR Physique et In
103. urrent e High efficiency at low speed e High power factor Advantages Disadvantage Figure 16 Advantages vs disadvantage The advance of powers electronics technology and the cost of these kinds of equipments have made a current utilization of frequency converter in the industry But frequency converters aren t used only with squirrel cage motors For example one another application is in the aerospace and airline industries Often airplanes use 400Hz power Frequency converter 50Hz or 60Hz 400Hz is needed to use in the ground power unit These power units are used to power the airplane while it is on the ground Other application in renewable energy systems frequency converters are an essential component of double fed induction generators as used in modern multi megawatt class wind turbines e document 15 TAMK University of Applied Sciences Departement of electrical engineering Frequency converter page 14 102 5 3 Frequency converter in the Coiler Drive mi VAGON DRIVEN BY DRIVES Figure 17 The two frequency converters Vacon NXP used The designation and its meaning of the frequency converter is in appendix 1 TAMK University of Applied Sciences Departement of electrical engineering PLC page 15 102 6 Programmable logic controller Now Programmable Logic Controllers PLCs represent a key factor in industrial automation Its use allows a flexible adaptation to varying processes also as rapi
104. x_Data_Len 56 Modul_Offset 0 Slave_Family 1 Fail Safe Max_Diag Data_Len 6 Module VACON PPO 1 0xF3 0xF1 EndModule Module VACON PPO 2 0xF3 0xF5 EndModule Module VACON PPO 3 OxF1 EndModule Module VACON PPO 4 0xF5 EndModule Module VACON PPO 5 OxF3 0xF9 EndModule Module i special 0x00 EndModule Module PPO 2 0xF3 0xF1 OxF1 0xF1 EndModule Module PPO 4 OxF1 OxF1 OxF1 EndModule Module PPO 5 0xF3 OxF1 OxF1 OxF1 OxF1 OxF1 EndModule TAMK University of Applied Sciences Departement of electrical engineering STEP 7 Projects page 75 102 Appendix 3 User manual Coiler drive project creation with STEP 7 Creating a project In this chapter it will be introduce what are the steps to create and use a project in STEP 7 every step will be explained 4 SIMATIC Manager To start the application double click on SIMATIC Manager shortcut When SIMATIC Manager is opened select New project the New Project window is opened like on the Figure 1 New Project User projects Libraries Multiprojects Name Storage path amp Coiler_Drive C Program Files Siemens Step s7proj Coiler 1 D S _Prol C Program Files Siemens Step s proj _Prol r S7_Pro2 C Program Files Siemens Step s proj 7_Pro2 r Name Type Coiler Drive Project v 5 Storage location path C Documents and Settings labra OK Cancel Help F
105. y project Open a ProTool project Figure 1 WinCC Create a new project with the Project Wizard Next step is to choose the configuration To operate the coiler drive one computer with an HMI interface and one PLC is needed TAMK University of Applied Sciences Departement of electrical engineering WinCC Projects page 83 102 Therefore Small Machine has to be selected then the Next button can be clicked Figure 2 E WinCC flexible Advanced Project Edit yew Insert Format Faceplates Options Window Help Da v x O2 RA The Project Wizard offers pre defined scenarios for a variety of plant configurations e Selectthe scenario that best matches your plant configuration Then select a STEP 7 projectin which you wish to integrate your HMI project Ifyou do not want to integrate it leave the field blank Click on Next to continue configuration HMI device and controller C Small machine Large machine penn eer 1 Distributed operation Screen navigation Control center and local operation m System screens Sma rClient Libraries Integrate an S7 project Project information ad A controller is connected directly to an HMI device Figure 2 WinCC Select project type In the next screen the HMI device has to be selected For this click on the picture of the device and select in the PC folder WinCC flexible Runtime Figure 3 This option means that the PC will be used like a HMI dev

Design and creation of an HMI and a PROFIBUS network

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